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EQ1030T47D-820 SERVICE MANUAL

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1. Electric System All the diameters of these circles are less than 60 1 265 2 245 A A pare ct 4 235 Clearance D Passenger side Cowl top grille end Before reassembling the wiper arm clean the core shaft as shown in the picture so that the arm will not be easily loose after assembling Adjust the cleaner nozzle Adjust the cleaner nozzle with the tool as shown in the picture Max adjusting range 10 Check the wiper intermittent relay Connect the wire as shown in the picture When the connecting pole is connected with negative pole of the bat tery and the test lamp is on the relay is in normal condition EL 9 5 140 6 125 7 345 8 310 Unit mm Suitable tool MAX 10 Nozzle hole bore diameter 0 8mm Electric System Radio Cassette and Antenna Adjustmen of the antenna rod Adjust the antenna nutted rod under following condition MW AM signal can t be received or very weak After installing the new antenna feeder cable or radio before the adjustment check the connection of harness and antenna or feeder cable for correctness Pull out the antenna completely Switch on the radio and tuning to loud the volumn of the speaker Round the1400KHz there is a broadcasting station whose signal is very weak nearly can t be heard Turn the antenna left and right to find a optimum position for the receiving result Note Don t over turn the nutted rod antenna half
2. The distance from booster connecting yoke pin center to booster installing surface must be adjusted to 120 9 5mm then lock the connecting yoke nuts BR 10 Brake System Vacuum Pipe Note Pay attention to the following points when installing the vacuum hose Do not put any oil on the vacuum hose and check valve Make the hose touch the upper protruding ring of the formed pipe SBR225B Insert the vacuum pipe to the vacuum hose and make the hose touch the upper protruding ring of the formed pipe Install the Nylon tube with single one way valve assy mee pay attention to the direction to booster to suction manifold or vacuum pump SBR247C Check Hose and joint Check the vacuum pipe joint and valve for sealing and check the improper connection and damage to inlet manifold Check valve Use the vacuum pump to check the vacuum Connect the booster side vacuum Connect the engine side no vacuum Booster side ro Engine Arrow to the engine side SBR826B BR 11 Brake System Front Brake Disassembly is 1 Caliper body 8 Caliper bracket 14 Insulation spacer 2 Hose joint core 9 Guide pin 15 Spring leaf 3 Dustproof 10 Dustproof 16 Left brake friction block with 4 0il drain screw plug 11 Piston alarm inductor assy 5 Rest pin 12 Sealing ring 17 Friction block assy 6 Dustproof 13 Damping spacer 18 Insulation spacer 7 Rubber bush
3. 13 Tighten the left and right gasket of half shaft bear ing one by one and measure the windage and preload force of driven gear Tighten the left and right gasket in turns to get the prescripive windage and preload force When check preload force turn the drive conic gear repeatly to lay bearing in the right position 14 Tighten the bolt of half shaft bearing s seat 15 Assembly lateral locking pin 16 Check the radial run out of main reducer driven gear by micrometer If the difference of clearance on different position is great it may caused by other reasons beside driven gear and differntial If the radial run out amont of driven gear is inner the prescriptive range while the clearance of differential hous ing on different position is great replace the drive and i driven gear or differential housing SPD247 17 Check gear contact area refer to the explanation of adjusting PD 24 Profeller Shaft and Differential Maintainance Data and Explaination Profeller Shaft General Explaination Wheelbase mm 2515 Rear wheel Single wheel Type of rear axle Single class hyperbola conic main reducer differential punch jointing axle housing Type of profeller shaft Single open Amount of tie in 2 Main Differential Gear ratio 4 875 Provided by JMC PD 25 Profeller Shaft and Differential PD 26 Steering System TOC TNO BES sin che tsstasecsissnueheata a E E seat ST 1 Check With the Vehicles fascist
4. SBR365A Be careful not to let the liquid spray on the painted surface it will destroy the painting film If it does clean it right away with clean water Be careful not to bend the brake pipe when disassemble the booster Check Check the rod length of output end Provide 66 7kPa vacuum for the booster with high strength of vacuum pump Check the push rod length Specified length 10 0 10 25mm Clearance between the rod and the master pump pis ton 0 1 0 5mm BR 9 Push rod length Brake System Assembly Note Be careful not bend the brake pipe when installing the booster If the U type clip pin is damaged replace it Add new liquid of 901 4 to meet the requirements of GB12 981 HZY4 May use other brand liquids which meet the requirements of GB12 981 HZY4 but two kinds of liquids are not allowed to mix up for usage Do not reuse unclean liquid Be careful not destroy the fixed bolt screws of the booster when installing if Proper installation angle may avoid destroying the screws by metal around the instrument panel holes 1 Adjust the push rod as shown in the right picture before installing the booster 2 Tighten the fixed bolts between pedal bracket and booster when installing the booster Length 120 3 5 3 Connect the pedal with the U type rod of the booster input end 4 Tighten the fixed nuts 5 Assemble the master pump based on the above steps 6 Exhaust based on the above steps
5. BF 17 Heater Heater Using of Heater Control panel 1 Change over switch no use 2 Fan switch 3 Operating mode chosen switch 4 Plug 5 Inside air circulation switch Fan switch There are five speeds provided from 0 to 4 At 0 position the fan stops and the wind will become even stronger from 1 to 4 speed successively Turn these switch to adjust to the satisfied mode if the heater is needed Operating mode chosen switch J blowing to your head 4 blowing to your feet A blowing both to your head and feet j inside heating and defogging w inside defogging Turn the switch to select the needed wind mode 1 Cab inside air circulating switch G circulating internal air Press this button to circulate the cab inside air and average the air thermal distribution Note The warm air is heated by the cooling liquid of the engine Its temperature depends on the temperature of the cooling liquid Please do not use the heating device too long when the engine is stop or idle otherwise it will wear out the battery and influence the normal driving BF 18 Heater Air Heater Parts Structure 12 Av 14 1 Left air pipe 8 Air inlet duct assembly 2 Air duct assembly 9 Plastic nut assembly 3 Middle air pipe 10 Heater assembly 4 Right air pipe assembly 11 Blower assembly 5 Defrosting pipe assembly left door 12 Heater control mechanismassembly 6 Defrosting nozzle assembly 13 Water inl
6. 1 Regular pound 2 Even noise 1 Some individual gear and tooth is broken 2 Gear clearance is increased or gear is damaged 3 Bearing is worn 4 Lubricating oil is not sufficient 1 Disassemble inspect clean or replace dam aged gear or bearing 2 Replace or add oil Disassembling Procedures and Notes for Transmission Assembly Disassembling procedures of transmission from the vehicle Disassembling sequence 1 Operating flexible shaft 2 Odometer driveing flexible shaft 3 Drive shaft 4 Parking brake assembly 5 Starting motor 6 Transmission assembly MT 2 Transmission Disassembling sequence and notes for transmission Disassembling sequence 1 Clutch release bearing assembly 2 Clutch release fork shaft and release fork arm assembly 3 Clutch case connecting bolt 9 8 grade 4 Clutch case 5 2nd shaft nut 6 Odometer flexible shaft sleeve sets 7 Connecting bolt 9 8 grade 8 Rear cover 9 Odometer drive gear 10 Distance sleeve 11 Connecting bolt 9 8 grade 12 Cover assembly MT 3 Transmission 13 Self locking spring and steel ball Take off 3 self olcking springs and 3 self lock steel balls from the transmission housing 14 Elastic pin sets 15 Fork shaft reverse S speed Before disassembling place all the fork shafts in neutral position Push the rear end of rork shaft reverse 5 speed so that it moves forward Then move the fork shaft backward to dismantle the shift
7. A B See maintenance data amp explanation for reference Total toe in angles 28 3 Change the middle tie rod length to adjust the toe in 1 Loose the lock nut 2 Turn the left and right joint of the same degree to adjust the toe in FA 7 Front suspension Make sure that the middle tie rod has less than 35mm length turned into the left and right joint this is to assure the same length of the middle tie rod left an right joint 3 Use the moment wrench to tighten the lock nut to the required value Tightening torque 25 28N m Front wheel turning angle 1 Turn the front wheel to the front move the vehicle ahead to set the front wheel on the turning angle test device A Outside B Inside 2 Turn the steering wheel left and right to the turn ing limit to measure the wheel turning angle Wheel turning angle See maintenance data amp explanation for reference VARI Limit bolt 3 Adjust the front wheel turning angle by the limit bolt if necessary FA 8 Front suspension Front Axle 16 1 Front wheel hub cover 9 Brake disc 2 Retainer ring 10 Front wheel hub inner bearing assy 3 Hex thin nut 11 Front wheel hub oil seal assy 4 Antifriction spcer steering knuckle 12 0il seal retainer 5 Front wheel hub outer bearing assy 13 Left dustproof assy front brake 6 Front wheel hub 14 Left steering knuckle 7 Wheel nut 15 Left steering knuckle arm 8 Front wheel bolt 16 Disc brake assy F
8. Leaf Spring Disassembly and assembly Lift rear part of vehicle mount supporting seat 1 Loose the lower enf of shock absorber and disassem bly U type bolt 2 Disassembly shackle of rear spring 3 Disassembly front pin RA 10 Rear Axle amp Rear Suspension Check Check if there are any crack on leaf spring If there are replace the spring Check if there are any abrasion crack distortion or damaged screw thread on front bracket shackle U type bolt and gasket If there are any replace the parts when necessary Check if there are any distortion or craze on all sleeves replace them when necessary Make sure that sleeves are correctly assemblyed Assembly 1 Wiper suds on rubber sleeve 2 Assembly shackle and front pin and tighten the nuts by hand 3 Assembly supporting plate and nut below leaf spring or axle housing 4 Tighten U type bolt in diagonal Tighten U type bolt to make them all in the same length on the scew thread part below the suporting plate 5 Assembly shork absorber and tighten nuts by hand 6 On non load condition shake vehicle to eliminate the damp of leaf spring 7 Thighten shackle front pin and nut of shock absorber RA 11 Rear Axle amp Rear Suspension Rubber Cushion Block Disassembly rubber cushion block Make sure front mark is on the outside of vehicle as the picture showed RA 12 Rear Axle amp Rear Suspension Maintainance Data and Explainat
9. then apply grease After greasing wipe off the excess grease Be sure to put the caps back on The table includes first 40 000km lubricating schedule You have to follow the schedule after the first several kilometers AA Running in maintenance mileage 1 500 2 500km GL 7 General yx Running in maintenance lubrication item amp Normal driving lubricating item Place of lubricatin Lubricating interval mileage X 1 000km A A 4 8 12 16 20 24 28 32 36 40 Slip yoke of steering drive shaft and spider bearing Door hinge Door lock glass regulator odometer flexible shaft Hub bearing xX x x x Main Adjusting Data Adjusting Items Standard Inlet val 0 35 Air valve clearance cold ae Exhaust valve 0 35mm Oil pressure of idling engine 69 100kPa Oil pressure of normal run engine 196 490kPa Water temperature of normal run engine 80 95 C Tension grade of alternator belt 10 1S5mm Free travel of clutch pedal 25 40mm Free play of brake pedal 20 25mm Steering wheel free play 10 Toe in 0 2mm Lubricant Engine lubricating system Lubricant Engine oil Engine cooling system Antifreeze anti rust coolant Transmission Manual operation special oil 75W 90 Main reductor Industrial gear oil 75W 90 Steering gear Power steering fluid ATF 2 Clutch amp brake system Bearing and ba
10. 3 Sliding block FR 6 2nd shaft reverse gear i Sliding sleeve Synchronizer gear hub 7 Needle bearing reverse l Synchronizer 8 Synchronizer gear ring 4th speed 9 Synchronizer assembly 3rd speed 4th speed Tighten the 2nd shaft with its front end upwards remove the retainer ring synchronizer gear ring and synchronizer assembly 3rd speed 4th speed Notes The disassembled retainer rings couldn t be mixed easa Ch T S e ENNA enea i nig 10 Synchronizer gear ring 3rd speed 11 2nd shaft 3rd speed gear and needle bearing 12 Retainer ring and thrust washer 13 2nd shaft 2nd speed gear and needle bearing 2nd speed MT 8 Transmission 14 Synchronizer gear ring 2nd speed 15 Synchronizer assembly 1st speed 2nd speed Remove the retainer ring and synchronizer assembly 1st speed 2nd speed Notes The disassembled retainer rings couldn t be mixed 16 Synchronizer gear ring 1st speed 17 2nd shaft 1st speed gear 18 Needle bearing 1st speed 19 1st shaft centripetal ball bearing When disassembling use bench press MT 9 Transmission Disassembling sequence for transmission shifter cover assembly Disassembling sequence 1 Backing lightswitch 2 Elastic pin sets 3 Speed selective shaft external rocker arm sets 4 Speed selective shaft sets 5 Speed selective shaft adjusting shim 6 Oil seal 7 Elastic pin 8 Speed selective shaft sets 9 Oil seal 10 Flat wash
11. AE teamed EEEE AEEA AA BF 12 Cab Safety Bell acres eae kt a Rn BF 13 Rear Mirror Outside Cab woo cccecceccesccsccssecesccssessecssesssccsscssseeesenaes BF 14 Cab and Cargo Body sages ecstatic eben eae eaaates BF 15 Chassis Frame CASSIS PAINS A EE shan sua haenanusetusdenendohls BF 15 Heater isin Of HCAter sh asisasoce siceha caste Sesion dass cadres an dadsrie ana T BF 18 Air Heater Parts Structure ec eeccccscceccssccsscssccseecssessecsseeseeceees BF 19 Special Service LOOM can iccss cathe cecil ace ta eter BF 20 Cab Cab 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 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 damaged during assembling or disassembling Shapes Removal amp lnstallation Removal Removal by bending up with flat bladed screwdrives 0 F nmg Removal Removal with a flat bladed screwdriver or pliers TT ka Removal Screw out with a phillips scre
12. Attention For drive system adjustable washers are used Afer disassembly flange the preload force of bearing has to be adjust Therefore final gear needs to be checked 1 Disassembly profeller shaft 2 Release lower nut Tool amount refers to Preparation 3 Disassembly connecting flange 4 Disassembly front oil seal 5 Afer fill the cavum of oil seal with multi purpose grease insert oil seal seat 6 Assembly flage set and drive gear nut 7 Assembly profeller shaft Tool refers to Preparation PD 9 Profeller Shaft and Differential Disassembly and Assembly Disassembly Disassembly profeller shaft After disassembly profeller shaft stuff the ouput port of trassmition case with a plug Disassembly axle casehalf shaft Refer to rear axle part Attention When disassembly profeller shaft take care to aviod damaging splin socket flange yoke and oil seal Assembly Fully Inject the recommendatory gear lubricating oil PD 10 Profeller Shaft and Differential Drive Gear 1 Hex nut 2 Flange 3 Dust thround 4 Oil seal ass y 5 Driving conic gear bearing 6 Adjusting gasket 7 Adjusting sleeve 8 Driving conic gear bearing 9 Adjusting gasket 10 Driving conic bevel gear 11 Rear asle final drive housing 12 Flange nut 13 Spring washer 14 Gasket 15 Adjusting nut 16 Adjusting nut 17 Inside outside track 18 Bolt 19 Bevel gear differential housing 20
13. BR 12 Rear Brake Disassembly Brake System 1 Rear left brake bottom plate assy 2 Dustproof 3 Oil drain screw 4 Joint core 5 Wheel cylinder shield 6 Piston 7 Rubber cup 8 Rear brake wheel cylinder body 9 Wheel cylinder spring 10 Shim 11 Left pull arm 12 Spring washer 13 Brake shoe plate assy 14 Fork 15 Spring seat 16 Brake shoe pressure spring 17 Spring seat 18 Rear brake drum 19 Return spring 20 Return spring 21 Fork 22 Ratchet wheel 23 Fork 24 Return spring 25 Return spring 26 Parking brake cable assy 27 Dustproof plug 28 Pull rod 29 Dustproof plug BR 13 Brake System Parking Brake System 1 Parking brake control lever assy 10 Rubber bush 2 Elastic clip 11 Rocker assy 3 Parking brake wire rope assy 12 Cotter pin 4 Bracket with welding nut assy 13 Pin shaft 5 Monotube clamping piece 14 Return spring 6 Monotube clamping piece 15 Parking brake wire rope assy 7 Flexible shaft shim 16 Connecting rack and welding nut assy 8 Bracket assy 17 Parking brake wire rope assy 9 Spring shim BR 14 Cab amp Frame BF TOC Cab Clip and Fasteners enu taed latest ta Maar te a BF 1 CA POU AMG ER AERA E EAE ATATA TN BF 2 DOORS eea a e ara a ae a A TN ER AOE BF 3 Instrument Panel is ioc seccsalaias cons savesdedessvaxessieacncnsduscansvolasaciacteivesaniactodietenesshs BF 4 Cab Interior Trims and Exterior Trims 00 cece cece ceeeeccesecescesseeeeens BF 5 SCAU EEEO E A
14. arm shaft 17 Lower transverse arm assy 18 Rubber bush assy 19 Limit block assy 20 Bolt 21 Rubber bush assy 22 Round head pin assy 23 Bolt 24 Propelling rod 25 Big washer 26 Rubber bush 27 Spacer sleeve When assembling the rubber part the final tightening has to be under such condition wheel on the ground no load Condition of no load with full fuel coolant engine lubricant and the spare tyre jack driver tool on the vehicle and the vehicle park on the level position FA 16 Front suspension Shock absorber Disassembly and assembly When disassembling and assembling the shock absorber never let the oil or grease touch the rubber parts Check Use the proper cleanser to wash all the parts except the non metal parts and then dry them with compressed air Make use of the compressed air to clean the non metal parts Check the shock absorber for loose or crack ad oil leakage replace if necessary Check the piston lever for crack deform or other damages replace if necessary Check the rubber parts for wear crack damage or deform replace if necessary Torsion bar spring Disassembly Make a location mark between the torsion bar and its adjusting arm and the fixed arm Torsion barar Fixed arm Location mark Measure the length of the extruding part of the adjusting bolt FA 17 Front suspension Disassemble the torsion bar adjusting arm from behind and draw out the torsion bar Dis
15. fixed 88 137 nut Steering knuckle arm and tie rod connecting nut 88 137 Driven arm transition arm bracket fixed bolt 52 627 Steering knuckle arm and steering knuckle fixed bolt 108 147 Steering limit bracket and frame fixed bolt 72 98 Steering knuckle and upper cross arm ball head fixed 78 98 nut Steering knuckle and lower cross arm ball head fixed 118 191 nut Rocker arm shaft nut 200 230 Middle pull rod clamp locking nut 25 28 Transition arm fixed nut 200 230 Driven arm fixed nut 160 190 Vehicle body front amp rear mounting bracket and frame 60 72 connecting part Front and rear fixed part of the vechile body 75 87 Front seat fixed bolt on floor 21 26 Rear seat fixed bolt on floor 43 55 Rear axke 3 way oil pipe joint and rear axle connect 21 25 ing part Fuel tank bracket and frame connecting part 21 28 Fuel tank band fixed bolt part 20 23 GL 11 General Part Tightening torque N m Muffler fixed bolt 32 38 Battery frame and frame connecting part 35 47 Battery pressure lever fixed nut part 19 24 Front bumper and cross member connecting part 19 24 Power steering oil pipe joint nut 30 40 Air filter bracket and longitudinal connecting part 21 28 Power steering pump adjusting nut 25 31 Power steering pump adjusting bolt 19 25 Alternator adjusting lever bolt and nut 13 19 Push lever bolt of clutch master cylinder 8 11 Clutch pedal brake lock locking nut 12 15 Clutch pressure disc and flywheel f
16. frequent CYQD32 engine maintenance in bad using enviroment The maintenance above is in the normal using environment but if the vehicle is used in a bad envi ronment for a long time it will be necessary to do the following maintenance more frequent GL 4 General A Dusty area B Frequent start in short time C Towing long trailer D Long tome idle speed E Extremely bad climate high temperature or bitter cold area Using Environment Maintenance Item Operation Maintenance Interval A B IC ID Oil and oil filter Replace Often All types Replace Often A E Fuel filter Replace Every 20 000km Clutch Maintenance Intervals X 1 000km A 4 8 12 16 20 24 28 32 36 40 Maintenance Items Check working condition of clutch Check clutch pedal free play Check hydraulic pipe line and pump for leakage Transmission i Maintenance Intervals X 1 000km Maintenance Items A 4 8 12 16 20 24 28 32 36 40 ki Kiki Ki Check transmission for oil leakage KiKi Ki KK KK KKK KK Check transmission oil level Kiki Check worn condition between transmission and propeller shaft spline Check the connections of control mechanism for looseness Replace transmission lubricant oil Brake system Maintenance Intervals X 1 000km 4 8
17. is as below O Ww ice GL 9 General Transmission Gear Oil The manually operated gear oil API GL 4 75W 90 is recommended Lubricating Grease The compound lithium grease is recommended but the general lithium grease could also be used Fluid for Brake and Clutch The DOT4 901 4 brake fluid is recommended Note Never use brake fluid with different quality or type Engine Coolant Long effective frostbite antirust fluid is recommended and its freezing point must be lower than the lowest local temperature for 8 C Tightening Torque Tightening torque of the important part Part Tightening torque N m Upper cross arm and ball connecting part 22 26 Ball joint and steering shaft connecting part 78 98 Buffer rubber and cross member connecting part 62 76 Distance rod front end locking nut 118 157 Distance rod and cross member connecting part 54 71 Lower cross arm fixed nut 108 147 Upper cross arm fixed part on the frame 108 147 Torsion arm and lower cross arm fixed part 50 68 Upper cross arm fixed nut of two ends 71 103 Adjusting nut on the adjusting arm S 082 Lower cross arm cotter pin fixed nut 118 191 Upper bracket nut of front shock absorber 32 42 Tighten nut of front shock absorber upperend 2 62 Nut of front shock absorber lower pin 32 42 Rear leaf spring U bolt and nut 100 105 The fixed part of rubber assist spring 35 47 Leaf spring pin and shackl
18. it will cause sulfating of the battery pole penal Although the sulfating battery pressure is very high at initial charging stage compared with normal battery its cur rent is not even enough smooth as shown in the picture Specific gravity check 1 Read hydrometer and thermometer indications at eye level 2 When the electrolyte level is too low the battery can be lilted is raise the liquid level so the measurement could be taken easily EL 3 nee Normal battery Sulphated batte Charging voltage p y t Charging voltage Charging current Charging current Duration of charge Read top level with scale mere gm Hydrometer fee Electric System Battery charging Charging per fixed current 7 0A can be used for initial charging until average pressure of the single battery reaches to over 2 4V then 3 0A can be changed for charging If the pressure change of the battery is not over 0 05 V h within 2 hours at the end of charging period the proportion of the electrolyte does not change obviously also taking temperature into consideration then the battery can be regarded as fully charged During the whole charging period the temperature of electrolyte should be maintained around 20 40 C taking the middle single battery measuring value as standard 10 0A can be used for normal charging until average pressure of the single battery reaches to over 2 4V then 5A can be changed for charging If
19. on ground no load After the assembly check the front wheel alignment and adjust if necessary See Wheel alignment of the Maintenance data amp explanation for reference Disassembly Press out the upper transverse arm shaft with a block Check Check the upper transverse arm shaft and rubber sleeve for damage and replace if necessary Check the upper transverse arm for deform or break and replace if necessary Assembly Wipe some soapy water on the rubber sleeve When pressing the upper transverse arm bush the bush has to be pressed into the proper position FA 21 Front suspension Install the upper transverse arm shaft and inside washer Install the inside washer by using of the fillet of inside machined surface Press the bush of the other end and the bush must be pressed into the proper position Tighten the nut for the moment Push rod Disassemble and assemble Disassenble the assembling nut of the lower trans verse arm and the frame Support the lower transverse arm by jack Assemble the push rod Confirm the correct installation of the bush and washer The final tightening of the rubber parts has to be under the condition of no load wheel on ground Check Check the push rod for deform or distort replace if necessary Check the rubber bush for crack wear or other damage replace if necessary FA 22 Front suspension Lower transverse arm Diasassembly and assem
20. strip BF 9 Cab Door outside molding CEUK EES VaR BF 10 Cab Pedal shield and pedal pad 1 Welded left side panel assembly 6 Clip assembly 2 Plastic nut assembly 7 Front bracket 3 Outer cover assembly 8 Buffering rubber nail 4 Pedal shield 9 Door lock dowel pin assembly 5 Pedal pad 10 Door sealing strip assembly BF 11 Cab Seat Note When assemble or disassemble the seat it should be maintarined clean and well Front seat BF 12 Cab Cab Safety Belt Notes eIf the vehicle in severely dashed in 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 Check support pin for tightness Check string for smoothness Check safely belt for damage Check botton amp clip fixing BF 13 Cab Rear Mirror Outside Cab ssembly view mirror a 5 Rear view mirror 7 Dome glove box with roo lamp assembly 6 Inside rear embly embly 8 Down view mirror ass embly rear view mirror bar ass BF 14 Cab Cab and Cargo Body Cab The following parts at least should be disassembled in the area of cab engine 1 Main electr
21. the 2nd shaft backward 3mm Put special tools into the ring groove and remove the bearing 24 2nd shaft assembly Take off the 2nd shaft assembly from the transmission case MT 5 Transmission 25 PTO coverplate bolt 6 8 grade 26 PTO coverplate 27 Reverse shaft stop pin After removing the PTO coverplate take off the reverse shaft gear stop pin from the transmission case 28 Reverse shaft Knock the rear end of reverse shaft with an appropriate metal bar and strike it towards the interior of transmission case 29 Reverse shaft gear assembly 30 Counter shaft 5th speed gear Remove the retainer ring and put it aside Then remove the 5th speed gear of coun tershaft inward and take it out with the countershaft assembly MT 6 Transmission Disassembling scheme and notes for 2nd shaft assembly and Ist shaft assembly Disassembling sequence of 2nd shaft assembly and Ist shaft assembly 1 Thrust washer 2 2nd shaft 5th speed gear 3 Retainer ring 4 Synchronizer gear 5th speed MT 7 Transmission 5 Synchronizer assembly reverse 5th speed Remove the retainer ring and the synchronizer assembly and then dis mount the synchronizer spring synchronizer gear sleeve sliding block and synchronizer gear hub 3 alin lee nil Notes As the dimension of each retainer ring matches the clearance of synchronizer gear hub respectively do not mix the disassembled retainer rings Synchronizer spring 3
22. the value of X is more than 53 85 first mount the shim press lst shaft centripetal ball bearing and then fit the retainer ring Apply lithium grease into the gear ring of Ist shaft and fit the Ist shaft assembly into the transmission case Then check whether the sliding block of synchronizer assembly 3rd speed 4th speed is inserted into 11 Countershaft front centripetal ball bearing 12 Countershaft rear centripetal ball bearing 13 Retainer ring MT 17 Transmission 14 Shifter fork 15 Shifter fork shaft 1st speed 2nd speed 16 Shifter fork shaft 3rd speed 4th speed 17 Shifter fork shaft reverse Sth speed Before assembling place the shifter fork shaft in neutral position Mount 2 steel balls on the position between Ist 2nd speed shifter fork shaft and 3rd 4th speed shifter fork shaft Insert the interlock pin into 3rd 4th speed shifter fork shaft Mount 2 steel balls on the position between 3rd 4th shifter fork shaft and reverse Sth speed shifter fork shaft 18 Elastic pin sets Never use second hand elastic pin replace with new elastic pin When assembling align the slot line f Incorrect Correct Ae AE 19 Distance sleeve 20 Odometer drive gear 21 Speed selective shaft rear cover assembly Apply seal gum to the joint face of rear cover the gum track must be continuous MT 18 Transmission 22 Connecting bolt 9 8 grade 23 Odometer shaft sleeve and odometer driven gear 24 Clutch c
23. which is neg ative earth pole otherwise diode of the engine will be damaged It is not allowed to use way of short circuit making fire jump from armature B to the body to check whether the motor generates power It is not allowed to dismount the main powered devices as battery while engine is in high running speed Common breakdown causes Motor not generate power Rectifier damaged Brush blocked and not touch the sliding ring Stator coil cut and short circuited or earthed Rotator coil cut and short circuited or earthed Motor power not enough Motor driven belt too loose Individual rectifier damaged Brush not connected well Sliding ring dirty and damaged Rotator coil short circuited Battery internal short circuited EL 4 Electric System Charging current too big Adjusting pressure of adjuster too high Battery internal short circuited Charging current too small Adjuster pressure value too low Motor abnormal noise Motor not well installed Motor bearing worn and loose Rotator and stator rub each other Coils of rotate and stator cut circuited diode cut and short circuited and electric appears Starting System Breakdown causes Motor not running Battery power not enough severely Starting relay not connected Armature coil cut and short circuited Drive gear shaft blocked Magnetic switch touching point burned and oxidized or not well adjusted Ignition switch damaged or not connected we
24. 12 16 20 24 28 32 36 Maintenance Items gt Check effectiveness of service brake and parking brake Check brake line for oil leakage X x wt Xt gt t ot Xt gt t Xt ot Xt e Xt 2b b gt t gt t Check remain hydraulic oil of clutch and brake system adka gt gt t gt e Check the tightness of the brake support plate Check brake pedal free play Xt gt t b E ot Xt 2b e Check brake shoe for wearing Check vacuum booster oil pipe and valve for oil leakage Check brake drum and brake disc for wearing Yt E b gt t b t Replace hydraulic oil of clutch and brake system Check parking brake lever and steel wire for the working condition Steering system Maintenance Intervals X 1 000km A 4 8 12 16 20 24 28 32 36 40 Maintenance Items Check steering gear and pipe for oil leakage Check the tightening condition of pitman arm Check the tightening condition of steering gear to thr frame GL 5 General Steering system Maintenance Intervals X 1 000km 12 16 36 Maintenance Items Check the tightening condition of tie rod ends and drag link joints Check the tightening condition of transition arm and driven arm Check steering gearing device for looseness Check steering wheel for free play and op
25. 2 PTV AUIS EIE E eae usecase E AO BR 3 1 3 211 2M Pipe eatneee eae ae er nec tm nO ne et eI Stee rome Sent One CSN eer BR 4 Brake Pedal and Bra Ce scsge vce vis eiuis tes cesar aatleesdocetasadn cer tene sine tasakeages ed BR 6 Brake BOOSL S ntsetssctcacth EE EE BR 8 Waa PIG ose epee be aa avn nc hate eben pasar eda con aie Houettnies BR 11 Eront Brake ssena ric IARC try a SM TE Melty a er eR Ar BR 12 SSE al DIA L Se Raa eT EC OR RS TEE Om TATE SY 8 OTTER ROE ERT REN ROT BR 13 Parking Br ke 5 V SLIM sap chee anuse ee ees a euna n R E ARa BR 14 Brake System Attentions Use brake liquid of 901 4 to meet the requirements of DOT4 May use other brand liquids which meet the requirements of DOT4 but two kinds of liquids are not allowed to mix up for use Do not reuse the exhausted and unclean liquid Be careful not to spray the liquid to the painted area this will damage the painting surface If the liquid sprayed out to the painted area without care wash it immediately with water Clean the main pump sub pump and brake dump with clean liquid The mineral oils as gasoline and coal oil are not allowed to use they will damage the rubber parts in the hydraulic system Disassemble the brake piping with tools Note Clean the friction lining with vacuum cleaner to minimize the air pollution caused by friction material and dust BR 1 Brake System Check and Adjust Check the brake liquid level MAX Check the level of th
26. A 9 Front suspension Hub amp Brake Disc Disassembly and assembly Dismount the brake caliper assembly The brake pipe need not to be dismount from the brake caliper and pay attention not to depress the brake pedal to avoid piston extruded Note Never distort the brake pipe Dismount the lower hub cover cotter pin and the adjusting spacer Dismount the hub bearing locking nut by proper tools Remove the hub bearing from the steering knuckle shaft Note Never let the outer bearing out Dismount the tortion bar spring See chapter Front suspension After assemble the hub and hub bearing adjust the bearing pretightening force Pretightening force adjustment After replace the hub bearing or hub the bearing pretightening force has to be adjusted The adjusting method 1 Before adjustment clean all of the parts first 2 Smear some lubricating grease on the following parts LA ubricating part Rubbing surface of the steering knuckle shaft Interface between outer bearing and locking washer av SFA406B Wheel hub cap Grease sealing ring edge FA 10 Front suspension 3 Tighten the bearing locking nut to the required torque 34 39N m 4 Turn the hub for several times to set the bearing in correct position 5 Tighten the bearing locking nut again to the required torque 34 39N m 6 Back the locking nut for 45 Use the hex nut Turning angle 45 7 Install the adjusting cap an
27. Adjust it betwen the ball head bolt center Standard length See Maintenance data and explanation 2 Lock the fixed nut of the tie rod to assure the consistent motion of two ends Note To assure the connecting pull rod screw up to 40mm length in the tie rod pipe ST 8 Steering System Check Ball head pin assembly 1 Check the ball head pin travel If there is damage too large axial clearance or hard move of the ball head pin replace the ball head pin assembly Transverse swing force measuring point cotter pin A See Maintenance data and explanation Driving moment B See Maintenance data and explanation Axial clearance C 0mm 2 Check the working condition of the dust proof If it had been damaged replace immediately a When replacing the dust proof pay much attention to it and do not damage it b Use the li based grease to lubricate the ball head pin if nec essary c Install the dust proof by the special tool and be careful never let the dust proof over expansion Note Be careful and never let the grease on the tapered part of the bal head pin Drag link and tie rod Check the tie rod and the related rods for any break bend or crack replace if necessary Fixing and adjusting part Check each connecting part bolt and cotter pin for any loose ness clearance or damage If there is looseness or extra clearance check the ball head pin for damage When reassembling the ball head
28. B is not in the required range replace the ball head pin Check the ball head pin vertical clearance C See Maintenance data amp explanation for reference If the clearance value is over than the required range replace the ball head pin Check the dust proof for damage Note If the ball head pin is new and the dust proof is damaged replace the dust proof under the quide of the pro fessional person If the ball head pin is in use and the dust proof is damaged replace the ball head pin assem bly Only replace the dust proof is forbidden FA 24 Front suspension Maintenance Data amp Explanation Torsion bar spring Length mm 1000 D Diameter mm 30 H Torsion bar spring SFA469B Shock absorber Diameter A mm 54 Diameter Bmm 45 A P Recover risistance N 2250 350 Compression resistance N 1000 200 SFA489B Check and adjustment Front alignment no load Wheel camber 0 25 0 35 Caster 0 15 1 15 King pin inclination 7 50 8 50 Difference value of left and right wheel alignment wheel camber caster king pin inclination less than 45 Toe in mm 0 2 Front wheel maximum turning angle Inside turning angle 35 36 Outside turning angle 27 29 FA 25 Front suspension Vehicle gesture no load Lower transverse arm shaft center Lower transverse arm central height H mm _ 139 145 SFA No load full fuel coolant lubricant and original tyre jack and driver tool vehi
29. EQ1030T4 7D 820 Light Commercial Truck Service Manual PEOPLE S REPUBLIC OF CHINA DONGFENG AUTOMOBIL CO LTD 2006 6 TOC General QD32 Engine Clutch Transmission Front Suspension Rear Axle amp Rear Suspension Propeller Shaft amp Differential Steering System Brake System Cab amp Frame Electric System General TOC Preventive Measures iss esa 5 cnc x3 Sehvaresieies ed saesbaices tacdevtedeceiad xtederdenpvenideadt GL 2 How to Use Miamiiall 43 acne aa ees Sea acho Bede GL 3 Maintenance SPCCITICAllOMS sce ciccs cacucasascaustsecacstactne eeraearee dee cegoreeonel GL 4 Grease Application Place and Schedule uu ccceeeeeteeeeeee GL 7 Main Adjusting Data scsi hss cincrecsenacsiettnsencenstecsdend ied cadeck da eoladendsatadacedevedls GL 8 I WDE CAIN sessile cates cet tebensntal E A treme betta EAA aol accus al GL 8 AAC YD a te EE cas tered cont uaa eae Seis eter ena san uaee GL 8 ib CARR tet ee nO eT eve A TEE ert Tn ener See GL 9 IPN OMeCnUDRICAM Gh Macias te Geel eels A hie Co a EA GL 9 Gear Olei eanne ce ke vacaciones E E erence ace GL 9 Transmission Gear Oilsic inst ox tiie itd oc cere en amauta GL 10 Lubiic ting LCA Cisse a cscs nat Guedes aa a E Manas GL 10 Fluid Tor Brake and Clute is cxsitacc cae tnatat ined art eeeei caste tansnas tease steed GL 10 Engine Coolant ere enea rind cata Seana e TAA cede teed ate GL 10 Tightening Torque ciciecs tects csccavasdervocsnacedsechiccatasdesciaeactig ate s
30. Exterior Trims Interior trims Side ard floor trims Passenger area Note 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 Disassemble the roof lamp ass y Disassemble the handrail Disassemble the seats Disassemble the safely belt Disassemble the door guardrail Disassemble the rear window glass 9 BS ee eo A D wearer G fp Zz er E cS R c 7a Plastic nut Gs ANE BF 5 Cab 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 Disassemble inner guard board of door front door door Metal clips BF 6 Cab Roof trims Disassembly of the roof trims Remove part of headlining from corner and gradually peel headlining off Headlining adhesive Cab Exterior Trims oN a m BF 7 Cab Front upper cover 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 Cab Front Panel Grill BF 8 Cab Front and rear window pane Cab door seal
31. FA 10 Steering IRIN bel pct ance at Sa aa net Ate at oe as ara eae gees FA 14 Front Independent Suspension cccceessseccececceesseeessaeeeeeeeeees FA 16 Maintenance Data amp Explanation 0 cccccccccccecccesesessseeeeeeeeees FA 25 Front suspension Notice When assembling the rubber part the vehicle must be in curb weight and the rubber part has to be screwed down after the wheels touched down the ground Curb weight the vehicle equipped with full fuel coolant oil and spare tyre jack service tools and parked on the level ground Use tool to disassemble and assemble hub When disassembling the suspension part check the wheel alignment and adjust it if necessary Preparation Special tools Tool name Description To disassemble the connecting part between ball head pin and steer ing kunckle Extractor Disassemble the ball head connection of tie rod and drag link Ball head pin replacer lt r Assemble the hub bearing Bearing punch D Disassemble and assemble bearing nut Wheel bearing nut wrench TT Front suspension Front Suspension Torsion bar Wd Upper transverse arm Lower transverse arm Sy Front suspension cross beam NH Thrust bar SFA399B FA 2 Front suspension Riding Inspection and Repair Note When assembling the rubber part the vehicle must be in curb weight and the rubber part has to be screwed down
32. Profeller Shaft and Differential Check the Axial Freedom Degree of Cross Axle Replace the cross axle of profeller shaft if it s axial fredom degree exceeds the limited degree Axial fredom degree amount refers to Maintainance data and Explaination Disassembly Disassembly cross axle 1 Mark the profeller shaft and flange yoke 2 Disassembly the clip 3 Knock the flange yoke with a hammer Be careful to avoid damaging the cross axle and the hole of flange yoke when disassembly the cross axle bearing SPD732 Profeller Shaft and Differential 4 Use the same approch to disassembly the other cross axle bearing Mark the disassemblyed parts in order to keep their former positions in the later assemly Assembly Cross axle 1 Assembly the cross axel bearing and lay the recom mendatory multi purpose grease on the inner side of bear ing Do not loose any needles in the needle bearing when assembly it Stock vive SPD133 2 Select a clip which could meet the demand of cross axle s axial clearance then assembly it The thickness dif ference value should be within 0 06mm 3 Knock the flange yoke to elimate the clearance between bearing and clip PD 7 Profeller Shaft and Differential 4 Check agility and axial freedom degree of cross axle Axial freedom degree refers to Maintainance data and Explaination Profeller Shaft and Differential Maintainance Replace Front oil Seal
33. Sub driving conic bevel gear PD 11 21 Differential bearing 22 Stop spacer 23 Bolt 24 Supporting washer 25 Planetary gear 26 Spring pin 27 pin of planetary gear 28 Half shaft thrust block 29 Half shaft gear 30 Supporting washer Profeller Shaft and Differential Disasembly Pre check Before disassembly drive differential check the following Preload force 1 Turn drive gear for several times to put bearing in its right position 2 Use tool check the preload force Clearance between driven gear and drive gear Measure the clearance of main reduct gear at different points with a micrometer gauge Radial run out of driven gear Measure the radial run out of driven gear with a micrometer gauge SPD247 Gear contact area Checking of gear contact area refers to Adjusting Clearance between half shaft gear and planetary gear Thickness gauge Use a thickness gauge to measure the clearance between the thrust gasket of half shaft gear and differential housing PD 12 Profeller Shaft and Differential Differential 1 Fixing main differential ass y by tool 2 Mark the seat of hakf shaft bearing with paint or a special tool to avoid mistaking in reassembly Since the bearing seat is linear bored in machining it should be in its former position when reassembly it 3 Diassembly locking pin of lower half shaft and bearing seat of half shaft 4 Disaaembly adjusting spacer of lower hafl
34. Suspension Rear axle and rear suspension Check rear axle and rear suspension parts for any looseness wear or damage Turn the left and right wheel to check if it is in normal con dition Retighten all the bolts and nuts to the required torque Tightening torque aim to the requirement of rear suspen sion Check the shock absorber for leakage or other damage Wheel bearing Axle end clearance 1 Check the bearing drive to see if it is smooth i OT 1 Dan ai gt ree Per 2 Check the axle end clearance l Ta f tte UN RA 3 Rear Axle amp Rear Suspension Rear Axle a IS gt OCs rN S o o 1 Rear axle half axle 9 Rubber seal gasket assy 2 Dustproof 10 Adjusting spacer 3 Half axle outer oil seal seat 11 Half axle inner oil seal assy 4 Half outer oil seal assy 12 Ventilation plug assy 5 Half axle bearing seat 13 Rear axle housing assy 6 Half axle supporting bearing 14 Seal washer 7 Lock spacer 15 Screw plug assy 8 Half axle bearing lock nut 16 Scerw plug RA 4 Rear Axle amp Rear Suspension Disassemble 1 Disassemble the parking brake cable and brake pipe 2 Disassemble the brake drum 3 Remove the bearing lock nut 4 Pull out the half axle by special tool Be careful not damage the oil seal when pulling the half axle 5 Disassemble the oil seal the disassembled oil seal can t be reused replace a new one 6 Make use of the screw driver to turn up
35. Wheel alignment of Maintenance data amp explanation 3 If the wheel alignment is not the same as the required value adjust the vehicle gesture See Wheel alignment of Maintenance data amp explanation 4 Adjust the wheel alignment See Wheel alignment of Maintenance data amp explanation gn p Wheel camber caster and king pin inclination Before check the wheel camber caster and king pin inclination set the front wheel alignment test device under the wheel then make the vehicle shock up and down for several times to limit the friction force and make sure the vehicle gesture is correct FA 5 Front suspension After the test if it is necessary to adjust the angle please follow the steps below First check the upper and lower ball head pin for wear and looseness the hub bearing for looseness and the steering kunckle for deformation Wheel camber zero load See maintenance data amp explanation for reference King pin inclination zero load See maintenance data amp explanation for reference Caster zero load See maintenance data amp explanation for reference Adjustment The change of the wheel camber and caster is through increase or decrease the ajusting spacer between shock absorber and upper transverse arm shaft err p Adjusting spacer Before increase or decrease the adjusting spacer lift the lower transverse arm by the jack hickness FA 6 Front suspe
36. ace if necessary 3 Check dust cover for cracks deformation or damage Replace if necessaty 4 Check piston spring for wear or damage Replace if necessary CL 5 Clutch Clutch Release Mechanism 1 Clutch driven disc 2 Clutch cover and pressure plate Removel and installation Install retainer spring and spring holder CL 6 Clutch Remove release bearing Install release bearing with suitable tolerance Inspection Check whether the release bearing has crackle and wear The release bear ing should run smoothly and noiselessly Change it if necessary Check whether the surface of the release bushing and release fork has wear damage and corrosion Change them if necessary Lubrication Lubrication the fit surface and the friction surface of the bushing and fork with recommended grease Warning Too much grease might result in damage to the clutch driven disc padciis veces Apply lithium based including molybdenum disulphide Clutch Driven Disc and Pressure Plate Clutch disc Do not clean in solvent When installing be careful that grease applied to main drive shaft does not adhere to clutch Clutch cover QD Apply lithium based grease including molybdenum disulphide CL 7 Clutch Clutch Driven Disc Check Check the wear of the driven disc The wear limit between the friction facing and rivet head 0 3mm Check up the spline tooth gap and its deviation for the driven di
37. after the wheels touched down the ground Curb weight the vehicle equipped with full fuel coolant oil and spare tyre jack service tools and parked on the level ground When disassembling the suspension parts please don t squash by the related parts Front suspension part Check the front suspension for loose crack wear or other damages 1 Shake front wheel 2 Confirm that the cotter pin is in ggod condition 3 Screw down all bolts and nuts again to the required torque Check the shock absorber for any leakage or damage SMA240 FA 3 Front suspension Chck the upper and lower transverse arm ball head dust proof for any damage crack or loose Warning If any of the above situation has happened replace the ball head pin in time and forbidden to drive the vehi cle Otherwise it may cause accident Check the vertical clearance of the ball head Upper ball head clearance lt 1 6mm 1 Lift the front part of the vehicle and set a footstep 2 Fix the dial gauge to the tie rod and set the contact of the dial gauge to the lower edge of the brake caliper 3 Make sure that the front wheel is in the straight driving line and the brake pedal has been pressed down 4 Insert a crowbar between the tie rod and wheel inner felloe Upper ball head Dial gauge SFA303A 5 At the time of pressing the crowbar observe the Max read of the dial gauge 6 If the ball head motion clearanc
38. age 1 500 2 500km y Running in maintenance items Normal maintenance items Note Customers should carry out the inspection and maintenance intervals according to the different area condition Properly shorten the maintenance intervals can ensure the truck to get the reasonable maintenance and move reliability Never prolong the intervals CYDQ32 engine R Replace J Inspect Replace if necessary A adjust C Clean D Dry and check Maintenance Intervals X 1000km Maintenance Items 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Replace lubricant R iR RI Ri RI RI_R I_RI_RIT_RIRI_RI_RIRIRIR Replace oil filter cartridge R R R R R R R R f Maintenance Intervals X 1000km Maintenance Items 1 10 20 30 40 50 60 70 80 Exhaust device and tighting of other nuts I Drive belt I I I I I Engine coolant R R Cooling system I I I I Fuel pipeline I I Air filter C C C R C C C R Air inlet and outlet valve A A A A A Fuel spray nozzle Wita 1 Idle speed I I I I I Note If the engine power apparently dropped or exhausted black smoke check the starting pressure of the fuel spray nozzle and fuel spray conditions and adjust if necessary If there is a in the maintenance item it has to follow the Maintenance in bad using environment and do the maintenance more
39. ance and then tighten the nut Input rod Push plate 3 Check the pedal free travel Lock niit Assure the brake light is off when releasing the pedal SEREG 4 Check the height of the pedal when depressing it under the running of the engine If the height is lower than the specified value check the system whether there is any leakage or with air or damage of the main pump etc and then conduct necessary repairs BR 7 Brake System Brake Booster Brake master pump with vacuum booster 1 Oil reservoir assy 2 Front chamber oil pipe assy 3 Rear chamber oil pipe assy 4 Vacuum booster with brake master pump assy 5 Nylon pipe with one way valve assy BR 8 Brake System Driving Inspection Control check Shut down the engine and depress the pedal for several times for any travel change Press down the brake pedal start the engine if the pedal slowly down a litle it is nornal Sealing check Start the engine for one or two minutes then shut off Press down the pedal for several times slowly if the first time pedal down more and both the second and third time down less the booster is normal Depress the pedal when the engine is running and then shut off the engine without releasing the pedal If no distance change after the pedal depressing for 30 seconds it proves that the booster is in good condition Booster disassembly Note Normal Abnormal Third Second First
40. ase assembly Apply seal gum on the joint face of clutch case the gum track must be continuous 25 Clutch case connecting bolt 10 9 grade 26 Ball end supporter 27 Release fork and dust cover 28 Clutch release bearing assembly 29 2nd shaft nut 30 Self locking spring and steel ball 31 Shifter cover assembly 32 Connecting bolt 9 8 grade Tightening torque value of each connecting bolt dur ing reassembling Position Torque N m Connection between backing light switch and shifter cover 29 39 Connection between filler plug and transmission cover 39 59 Connection between drain plug and transmission cover 39 59 Connection between PTO coverplate and transmission case 10 25 Connection between odometer shaft sleeve and rear cover 11 19 Connection between shifter cover and transmission case 15 25 Connection between 2nd shaft nut transmission case 147 196 Connection between clutch case and transmission case 69 93 Connection between rear cover and transmission case 15 25 MT 19 Front Suspension TOC Notice amp Preparation issexccscaiscssst stl tac saad cpus tic tanieninisnitetee a stetccchsats FA 1 Front Suspension c cccccccccccsesscscsesecscsesescsesscecsesecscseseceesesecscsesececseescseseees FA 2 Driving Inspection and Repalt ccccccccccccsccscscsssscsesecscscseeecseseessseseees FA 3 EINE eI Si ces a sea ea xu cess Edema Wea esi AL Sia A E Bal FA 9 LUISE Brake Disterna e 2 at eager yee acta ee eta
41. assemble the torsion bar fixed arm Check Check the torsion bar for any wear deform bend or any other damages Check the parts serrating spline for crack wear distort or other danages Assembly and adjustment Along the tightening direction to adjust the adjusting nut of the adjusting arm Never adjust the nut along the nut loose direction 1 Install the torsion bar fixed arm to the lower trans verse arm 2 Wipe a layer of grease on the spline tooth of the tor sion bar 3 Adjust the lower transverse arm position to assure the alignment of both the torsion bar mark and its adjusting buffer block Lower transverse arm mark arm FA 18 Front suspension 4 Install the torsion bar spring When install the torsion bar spring please pay atten tion to the mark on the end of the spring Don t install in wrong direction 5 Install the adjusting arm Make sure the vehicle is in no load Locking nut Make the same extending length of the fixed bolt and the extending length before disassembling and then Q Adjusting bolt screw down Tighten or loose the adjusting nut to adjust the vehicle gesture and before tightening there should be loose first and then tighten up as required After adjusting the vehicle body gesture tighten the Adjusting arm locking nut to the required torque Tightening torque 108 127N m 6 With the wheel on ground vehicle no load shock the vehicle to eliminate the friction fo
42. ber cover 4 Be careful not shake or turn the bulb while removing N to remove Q 4 Note LY S Do not place the bulb outside the reflecting cover for long time otherwise dust gas or smoke will go into the light to affect the function of the light So the bulb can be removed only when replacing 5 The steps for installing is just on the contrary of removing Focus adjustment Use a focus device focus screen or head light tester when focusing Note Keep all the tires at normal pressure EL 6 Electric System Keep the vehicle and the tester at the same level No load on the vehicle except the driver on place the same weight on the driver s seat Low beam Switch on the low beam Make beam focus adjustment by adjusting screws First tighten all the adjusting screws and then loosen them to adjust Beam forcusing adjustment As shown in the picture adjust the head light to make its main shaft of the light parallel with the center line of light shaft and overlapped with point P The beam focus adjustment shown in the picture is suitable to the right side drive area The dotted line in the picture stands for light shaft centerline H Paralleled center line WL Distance between centerline of two head lights pre 5 000mm e 138 4mm Combined Instrument Panel EL 7 H Horizontal center line of headlamps 4 i Height of Vertical centerline lamp centers ahead of headlamp
43. bly Disassemble the lower fixed nut of the lower shock absorber bracket Disassemble the torsion bar spring See Torsion bar spring disassembly Disassemble the fixed nut of push rod See Disassembly and assembly of the push rod Disassemble the lower transverse arm ball head pin from the steering knuckle See Front axle steering knuckle 47 Special tool disassemble the lower transverse arm fixed nut Dismount the rubber bush of the lower transverse arm shaft from the frame by the proper tool When assembling the rubber bush wipe some sopy water on the bush face After assembling the lower transverse arm adjust the front wheel alignment and vehicle height See Front alignment of Examine and repair Check Lower and upper transverse arm Check the lower and upper transverse arm for damage and crack replace if necessary Lower transverse arm bush Check the bush for deform or other damage replace if necessary FA 23 Front suspension Upper and lower ball head pin Disassemble and assemble Disassemble the upper and lower transverse arm See Steering knuckle Check Shock at direction A see the the right figure and check the ball head pin See Maintenance data amp explanation for reference If the torque A is not in the required range replace the ball head pin Check the ball head pin for its driving torque B See Maintenance data amp explanation for reference If torque
44. circle is allowed Antenna position Radio cassette EL 10
45. cle is parked on the level ground Ball head pin Upper ball head pin Lower ball head pin Swing force A N Measure position cotter pin hole TS AARE Driving torque B N m 1 0 4 9 1 0 3 9 Vertical clearance limit C mm 0 1 1 0 0 1 1 0 Hub bearing Hub bearing locking nut 34 39 Tightening torque N m Loose locking nut first then tighten again N m 34 39 Withdrawal angle 45 120 Hub bearing driving moment N m 9 8 27 5 Axial clearance mm 0 FA 26 Rear axle amp Rear Suspension TOC PR CC AUC thc cosas acs ee es cise saelie sti escent te Alcs RA 1 Rear Axle and Rear Suspension ccccccccccccccscssescseseseseseseceesecscseseees RA 2 Rear NIC raie A Oda Osis alg a Reta ECS atcha ta RA 4 Rear Suspension soena econ ee ata eee elal a kd oon uae RA 9 Maintainance Data and Explaination 0 ccc eeeeeseseeeeteteeeeees RA 13 Rear Axle amp Rear Suspension Precaution Assemble the rubber parts under the vacuum conditions tighten them at last No load Full fuel coolant and oil equipped with spare tyre jack and driving tools Use the tools to disassemble and assemble the brake pipes Every time the suspension part is moved the front wheel alignment must be checked and adjust it if neces sary RA 1 Rear Axle amp Rear Suspension Rear Axle and Rear Suspension Rear lifting lug Axle housing Shock absorber SRA544A RA 2 Rear Axle amp Rear
46. d new cotter pin and back the locking nut for 15 or less to install the cotter pin FA 11 Front suspension 8 Measure the wheel hub bearing tightening force and shaft end clearance Shaft end clearance 0mm Bearing tightening force at the hub bolt Standard torque 0 7 101N m Spring balance read 9 8 27 5N Repeat the above procedure until obtain the correct bearing tightening force 9 Bend the cotter pin 10 Install the hub cover SFRA417 Disassemble Disassemble the inner oil seal Use a propper copper bar to disassemble the bearing outer ring S Copper bar Check Clean the hub bearing and hub Hub bearing Make sure if the bearing could be in free rotation and whether there are noise crack dent and wear or not Hub Check the hub for crack by magnetic particle inspection FA 12 Front suspension Assembly Use the proper tool to install the bearing outer ring into the hub ee Proper tool Smear some grease on the bearing tapered face Lubricating part SFA406B Smear some grease on the flange part of the oil seal and then install it in the hub lt gt Inside SFA747 FA 13 Front suspension Steering Knuckle Disassembly Use special tool to dismount the steering tie rod Install the check nut on the check bolt in reverse to protect the bolt Dismount the steering knuckle from the ball head connecting part 1 Loose Don t dismount the upper and
47. e Replace leaf spring pins and sleeves Check the working condition of front independent suspendion rubber limit block Check the vehicle left and right height If the ball pin dust cap is damaged replace it immediately because it may damage the ball pin and cause danger in driving Propeller shaft Maintenance Intervals X 1 000km 4 8 12 16 20 24 28 32 36 Check shaft connecting part for looseness Maintenance Items Check tightening condition of spider bearing of propeller shaft Check propeller shaft splines for wear and damage GL 6 General Axle amp wheel Maintenance Intervals X 1 000km Maintenance Items 16 32 Ta Clean front rear axle assembly and wheel assembly Check main reductor for oil leakage Check tire pressure and wheel bolt and nut for tightening torque Check tire for wear and damage Check lubricant level of main reductor and clean the vent plug pt pt pe ae e yp pt pt pe eft Rotate tires Replace the main reductor lubricant Other Maintenance Intervals X 1 000km 4 8 12 16 20 24 28 32 36 Check the connecting part tightening conditions of cargobody to frame Check thelongitudinal and cross member of the cargo body for loose ness and damage Ma
48. e fixed nut Q341B12 80 102 Leaf spring pin fixed bolt Q151B0818 16 22 Nut of rear shock absorber upper pin 46 62 Nut of rear shock absorber lower pin 46 62 Engine rear mounting cushion and cross member con 88 108 necting part Engine rear mounting bracket and cushion connecting Follow EQB 37 1999 part Transmission bolt and rear mounting bracket connect Follow EQB 37 1999 ing part GL 10 General Part Tightening torque N m Transition output shaft and propeller shaft connecting 69 78 part Transition control flexible shaft fixed bracket and lon 13 16 gitudinal member connecting part Fixed bolt of flexible shaft two ends ball joint 25 30 propeller shaft and rear axle connecting part 69 78 Brake pipe joint 15 22 Front wheel nut 118 147 Rear wheel nut 118 147 Engine front mounting bracket and cylinder connect 30 41 ing part Engine front mounting cushion nut 46 56 Engine and clutch housing conneting part 39 49 Engine exhaust pipe and vehicle exhaust pipe connect 51 65 ing part Steering wheel locking nut 29 39 Steering gear and steering gear drive shaft universal knuckle fork connecting nut ete Steering gear and frame connecting nut 88 98 Steering drop arm locking nut 235 265 Drag link and drop arm connecting nut 88 137 Drag link and transition arm fixed nut 88 137 Middle pull rod and driven arm transition arm
49. e is beyond the required value disassemble the ball head and check and replace it if necessary Front wheel bearing Check the wheel bearing for smooth operating Check the shaft end clearance It is forbidden to have clearance in the shaft end If the shaft end has clearance or the bearing operates unsmoothed adjust the bearing pretightening force FA 4 Front suspension As for the front wheel bearing pretightening force adjustment please take the reference of other chapter Front wheel alignment Radial runout Before check the front wheel alignment do the fol lowing primary inspection runout Primary inspection 1 Check the tyre for wear and the tyre pressure standard pressure 530kPa 2 Check the inside and outside radial runout of the wheel assembly Outside radial runout value inside radial runout value X 0 5 Radial runout limit value 0 8mm Lateral runout limit value 0 8mm 3 Check the front wheel bearing for looseness 4 Check the front suspension for looseness 5 Check the steering pull rod for looseness 7 6 Use the standard vibration to test the shock absorber Pushirod locie bolt for normal work 7 Measure the vehicle gesture no load A B mm Reference to Maintenance data amp explanation 1 Shock the front part of the vehicle for 4 5 times to make the front suspension do the relative motion to confirm the correct vehicle gesture 2 Measure the wheel alignment See
50. e reservoir it should be between MAX and MIN MIN If the level of the liquid is too low check whether the brake system is leaking If the brake warning light is till on when releasing the hand brake rod check whether the parking brake control system is adjusted to the right position Check the brake pipe Note If the leakage is from the joints tighten or replace the damaged parts 1 Check whether the brake piping is broken or aging or has other damages replace the parts if necessary 2 Depress the brake pedal to the end to check whether the oil is leaking when the engine is in running Brake liquid replacement Fill up with 901 B brake liquid 1 Use a nylon pipe to connect each exhaust valve 2 Exhaust the brake liquid by depressing the brake pedal 3 Add new brake liquid until it flows out from each exhaust valve Exhaust out the oil from hydraulic system with the same steps and add new liquid Exhausting steps are refereed to Exhaust part Note Do not reuse the exhausted and unclean liquid Be careful not spray the brake liquid on the painted area it will destroy the painting film If you do it carelessly clean it at once with water BR 2 Brake System Exhaust Note Monitor the level of the liquid in process of exhausting Add new liquid of 901 4 in to the reservoir to assure it is always full during the whole process Place a container under the main pump to avoid liquid coming
51. eeecseseeseseeeens EL 8 Radio Cassette and Antenna ccccccccccccccssscecsscssssccoesscecesccsenceceenss EL 10 Electric System Electric System Harness Connector All the terminals have been improved which could prevent from loosening and disconnection Terminals could be loosened by pressing and pulling lock parts Note Don t pull electric wire while disconnecting terminals Example Standard Relay Relay can be divided into three types open close and mixed Normal open relay Normal closed relay Mixed type relay Does not flow Flows gt Flows mesmas Does not flow 2 Switch off _ o o w1 BATTERY sw1 BATTERY sw1 BATTERY Flows smmm Switch on U swi BATTERY EL 1 Electric System Fuse Wire and Fusible Link Fuse wire If the fuse wire is broken the problem must be solved before replac ing the fuse wire OK Burrned out Use proper fuse do not use the fuse with much higher than rated TN F value ura ats Insert the fuse box correctly do not slope it Take off the fuse wire of the clock if the vehicle is not used for long time Fusible link The melted fusible link can be seen with eyes if not sure check it with a electric measuring device and a check lamp Note If the fusible link is melted maybe the key circuit breaks down power line or big electric flow circuit Under such condition carefully check and solve the problems Battery Caution Start the engine w
52. el 37 External wheel 28 ST 2 Steering System Steering Wheel and Steering Column Steering Wheel e Remove the horn button Horn button Clamp e Disassembling the steering wheel by using special tools VAS C NSN gt S 7 ST 3 Steering System e When installing the steering wheel apply a layer of multi purposed grease on the whole surface two parts of the automatic return back pin of steering indicator and touch point of the horn e Install the steering wheel on the column shaft at the central position e After installing turn the steering wheel make sure to have a smooth movement and the same turning cycles on both left and right side at the central position Steering Column e When fixing the steering column first screw all the lock bolts of lower bracket and clips with hands and then re tightening again to make sure no extra pressure will apply to the steering column e When fixing the steering spline shaft make sure that the tightening bolts and the sunken part of the shaft are correctly faced to each other Disassembly and Assembly Steering lock option Lower joint ass y e When assembling and disassembling turn on the steering lock with the key e Be sure the surface of the spring lock ring after installing faces with the shaft e Before putting the shaft into the sleeve install the spring lock ring ST 4 Combination switch Column shaft a
53. er 11 Speed selective shaft internal rocker arm 12 Flat washer 13 Shifting shaft reverse limit spring MT 10 Transmission Check and Repair If wear of part damage of part or other fault is found through inspec tion repair or replace it 1 Thickness of shifter fork mm Standard Limit 10 0 9 0 2 Free length of self locking spring mm Standard Limit 31 6 30 1 3 Clearance between synchronizer gear ring and the end face of joint tooth mm Ist 2nd 5th speed 1 5 0 5 3rd 4th speed 0 5 4 Clearance between synchronizer gear ring and sliding block mm Standard 2nd 3rd 4th 5th speed 4 34 4 66 Ist speed 4 84 5 16 Cleanace 5 Clearance between synchronizer gear hub and sliding block mm Standard 0 09 0 31 MT 11 Transmission 6 2nd shaft radial runout mm Limit 0 1 7 Clearance between gear orifice and 2nd shaft mm Standard Limit 5th speed 0 05 0 08 0 2 8 Clearance between the liner and reverse gear shaft mm Standard Limit 0 04 0 08 0 2 9 Radial runout of centripetal ball mm Limit 0 2 MT 12 Transmission Reassembling Procedures and Notes for Transmission Assembly Reassembling of Ist shaft and 2nd shaft assembly as showed in the figure Assembling sequence 1 1st shaft centripetal ball bearing Use bench press when assembling 2 Needle bearing 1st speed 3 2nd shaft 1st speed gear 4 Synchronizer gear collar 1st 2nd
54. er cut off the hydraulic pipes block the open with clean staff to avoid dust entering Check Check whether there is any crack wear of the brake piping pipes and hoses replace if there is Installation Note Add new liquid of 901 4 Do not use exhausted and unclean liquid 1 Tighten all the expansion nuts and bolts Tightening torque of the nuts 15 18N m Tightening torque of the bolts 17 20N m 2 Add new liquid until it flows out from the valve 3 Exhaust air based on the above steps BR 5 Brake System Brake Pedal and Pracket Disassemble and assemble 1 Pedal bracket assy 2 Support shaft 3 Brake lamp switch assy 4 Return spring 5 Brake pedal 6 Rubber mat 7 Vaccum booster with brake master pump Assembly Check the following items of the pedal Whether the pedal is bent Whether the pin is damaged Whether the welding area is cracked Whether the pin head is cracked BR 6 Brake System Adjustment Check the free height from pedal to reinforced plate Free height 169 175 mm Note The booster rod couldn t be in a pressed position when assembling the booster head pin Adjust the pedal height if necessary Adjustment Stay inside Sa 1 Loosen the lock nut turn on the booster rod to adjust the pedal height then tighten the nut Assure the pushing rod head end on the inner side of the pushing board 2 Loosen the lock nut to adjust the light switch clear
55. erating Check steering gear oil level add if necessary pepe pepe e yp Check spline hub of the steering drive shaft for wear Xt b gt t gt gt t gt t 2 gt t E b 2 gt t amp Check and adjust front wheel toe in Check the tightening condition of upper and lower cross arm ball head to steering knuckle gt a eX ae Xa Da Xa Xa a Da Clean steering gear and pipe replace steering gear oil Check front wheel alignment Check the pull rod ball head working condition of the steering system X Suspension system Maintenance Intervals X 1 000km Maintenance Items A 8 12 16 20 24 28 32 36 40 Check shock absorber for oil leakage and fasten bracket bolts wk Kk lk lk ikki KK x Clean rear leaf spring and shock absorber sk Klik kx xx x kx x x x e a Check the working condition of torsion bar fixed adjusting arm wk Tighten U bolts and nuts of leaf spring during full load wk ae the working condition of front suspension torsion bar and push ke ve a pe ee condition of front independent suspendion upper ke n Tighten the connecting bolt of front independent suspension PAA Check the tightening condition of leaf spring shackle bolt wk Check the working condition of rubber assist spring wk Check leaf spring and shock absorber for any damag
56. et amp outlet pipe 7 Defrosting pipe assembly right door 14 Nylon strap BF 19 Heater Special Service Tool Name Explanation Disassemble the clutch Clutch special wrench drive disc Snan so sidetacher ani Disassemble and assemble the shaft seal installing device Filling device AA eibgealant Clutch disc tightening Disassemble the shaft seal nut a aie ae and the clutch drive disc Disassemble the belt pulley Pull device wheel Belt pulley wheel a Assemble the belt pulley wheel installing device Shaft seal guider Assemble shaft seal Socket wrench Disassemble locking nut As for the operating method please see the tool service manual for detail BF 20 Electric System TOC Harness Connector es cbcsdecetttener re thniced aawlebitsstdnc dae bec cxsenle antec lactdndire EL 1 Standard Relay cA sellin Saket Aisa ce hae oe hoe ea a EL 1 Fuse Wire and Fusible Link ios occci2se Secaccttasctacosecaatacecteeomecser a cotcantens EL 2 Battery cece cere een a errr Or tera eRe ter Stee Men wee ear CIEL ONT err eres Geert EL 2 CHAOS SV StS MMos tesis ea e aa tata aaie e aga aa EL 4 Startna Syste N eree a E ARE EL 5 Combined Switches s s ssssesissssesissssesisessesisisinsisesansisersnsisnsnnnisisresinenens EL 6 Front Head Lights heroe ee Ah Erap A EAP SaR SEE EL 6 Combined Instrument Panel 0 0 0 cccceccseceeseseeesseeeeeseseeesseeeeeees EL 7 Windshield Washer and Wiper ccccccccccscscsesseecseseeecses
57. grease on the edge of the oil seal RA 7 Rear Axle amp Rear Suspension 7 Put lithium based lubricating grease into the flute of the axle end cover 8 Put lubricating grease into the Spline slot of half shaft and wipe lubricating grease on the half shaft s surface where need to be lubricated ee Lubricate Part SRA756 9 Adjust clearance of axle end Cover of heel beari 10 Select gasket end face gasket era ene Seal ring of bearing cover Cover of axle Half shaft 11 Assembly half shaft by guide tool When assembly half shaft pay atttention not to dam age oil seal Special tool 12 Measure clearance of axle end Clearance of axle end Check the half shaft of both sides One side half shaft Left or right 0 4 1 6mm The other side half shaf 0 02 0 15mm 13 If the clearance of axle end is not in prescriptive range select gasket of end cover again When adjust the clearance of axle endpay atttention not to damage oil seal RA 8 Rear Axle amp Rear Suspension Rear Suspension Structure Summary RA 9 Rear Axle amp Rear Suspension Shock Absorber Disassembly and assembly Loose the nut of uper and lower end to disassembly the shock absorber Check If there are any oil leak crack or distortion on shock absorber it has to replace the shock absorber ass y If there are any crack or distortion on rubber sleeve it has to replace the rubber sleeve
58. ic 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 2 Hand brake operation and brake drag wire 3 Electric system wire harness and tube H i H Rubber pad 1g Cargo body First disassemble the following part 1 Rear combination light system and license lamp BF 15 Cab Cargo Body Installation 1 Front board assy 9 Main sill supporting base plate 2 Left side board assy 10 Left rear mudguard assy 3 Right side board assy 11 Buffer stopper 4 Rear board assy 12 Left locking device assy 5 Locking bar assy 13 Aixs pin 6 Rubber gasket 14 License fixing plate assy 7 Rubber base plate 15 Left rear locking bar 8 Left rear mudguard 16 Cargo body bottom plate assy Notes Different model has different shape of cargo body BF 16 Chassis Frame Chassis Frame Chassis Frame 1 Front bumper 10 Engine rear mounting cross member assy 2 Left side member 11 3rd cross member assy 3 Front tow hook 12 Cross member 4 1st cross member assy 13 Shock absorber cross member assy 5 Left gusset assy 14 Cross member 6 Right side member 15 Cross member 7 Right side member gusset plate assy 16 6th cross member 8 Front mounting cross member assy 17 Rear tow hook assy 9 Body angle iron
59. ifferential Differential Seat 1 Assembly the outside track of front and rear bearing Hammering the outside track of J front bearing 2 Select adjusting gasket of drive gear Refer to the explaination of adjusting 3 Assembly adjusting gasket of drive gear insert the inner taper of drive gear s rear conic bearing by tool 4 Assembly the inner taper of drive gear s front conic bearing PD 21 Profeller Shaft and Differential 5 Put universal grease in the cavum of oil seal s lip Assembly front oil seal 6 Reassembly bearing gasket of drive gear adjusting gasket of bearing and drive gear on gear seat 7 Knock connecting flange by soft hammer softly and assembly the flange on drive gear 8 Tighten the nut of drive gear by prescriptive torque PD 22 Drive Conic Gear Adjusting Gasket of Bearing SPD712 Profeller Shaft and Differential 9 Turn driver gear repeatly and measure the preload of the drive gear bearing 10 Assembly the differential housing which has the outside track of half shaft bearing into the gear seat 11 Turn adjusting gasket softly by special tool to lay the gasket on a suitable screw thread connecting position of gear seat 12 Point at the marks on bearing cover and gear seat then assembly the bearing cover Do not screw too tight to lock the adjusting gasket of bearing PD 23 Profeller Shaft and Differential
60. ing arm and shift ing device 16 Fork shaft 3rd speed 4th speed Push the rear end of fork shaft so that it moves forward Then move the fork shaft backward to dismantle the shifting arm and shifting device Prevent the front mounted interlock pin and steel ball from falling out Take out the inter lock pin from the front end of the fork shaft and then remove 2 steel balls from the transmission case At this time be care ful not to mix or lose them 17 Fork shaft 1st speed 2nd speed Refer to the above for disassembling procedures Take 2 setting steel balls from the transmission case Be careful not to mix up or lose them MT 4 Transmission 18 Shifter fork 19 Retainer ring countershaft rear bearing 20 Countershaft rear centripetal ball bearing Strike the front end of countershaft with copper bar or hand hammer and move the countershaft backward 3mm Remove the retainer ring place special tools into the ring groove and dismount the bearing 21 Countershaft front centripetal ball bearing Strike the rear and of countershaft with copper hammer move the countershaft forward 3mm Place special tools into the ring groove and remove the bearing 22 1st shaft Hold an appropriate bar against the outer ring of Ist shaft bearing and then strike the outer ring of bearing towards the front of transmission 23 Centripetal ball bearing rear of 2nd shaft Strike the front end of 2nd shaft with copper hammer and move
61. ing to the following procedure Carefully monitor fluid levlel at master clinder during bleeding operation 1 Fill in reservior with rocommended brake fluid 2 Connect a transparent plastic tube to air bleeder valve 3 Fully depress clutch pedal several times 4 With clutch pedal depressed open bleeder valve to release air 5 Tighten the bleed valve 6 Repeat steps 3 and 5 above until brake fluid flows from air bleeder valve without air bubbles CL 3 Clutch Clutch Control System Clutch master pump 1 Oil intake joint 11 Limit screw 2 Dual wire clamp 12 Rubber cup 3 Pump body 13 Piston 4 Return spring 14 Retainer ring 5 Piston oil intake valve return spring seat 15 Push rod thread fork 6 Piston oil intake valve return spring 16 Hex thin nut 7 Piston oil intake valve oil seal 17 Push rod spacer 8 Piston oil intake valve 18 Push rod 9 0il pipe joint 19 Dustproof 10 Limit screw seal ring CL 4 Clutch Disassembly and assembly Push pistion into cylinder body with screwdriver when removing or tightening valve stopper screw Qono CE Groove Align groove of piston assembly and valve stopper when installing valve stopper screw J Clutch slave pump 1 Slave pump push rod nut 5 Rubber cup 2 Shield 6 Pump body 3 Push rod 7 0il drain screw plug 4 Piston 8 Dustproof Inspection 1 Check rubbing surface of slave cylinder for wear rust or damage 2 Check piston cup for wear or damage Repl
62. intenance Items Check connections of cab for looseness Check chassis frame rivets for looseness Check battery electrolyte level fill up if it is not enough Periodic Replacement Periodical replacement parts are hose which deteriorate with lapse of time These parts are mainly rubber parts such as brake hoses fuel hoses It is difficult to predict the safety of these parts when checking them with the method used in the usual predict inspection Hence applicable parts must be replaced whether they appear to be usable or not Replace Intervals Year Replace lies 2 475 6 7 8 9J 10 11 12 Rubber parts of brake valves kikik kjk xix Rubber hoses of brake system kikik xix xix Rubber hoses for vacuum pump Rubber hoses of clutch control system Rubber sealing ring of master and slave cylinder of clutch ea ae suspension upper and lower cross arm ball pin klk ge Ve lhe te te Ite te te te Propeller shaft spider assembly gt ab ab ab ab ab ab ab ab ab ab ab Steering drive shaft spider ball pin assembly Km lI Kw KKK KKK Grease Application Place and Schedule Greasing should be performed periodically for all parts of the vehicle Before filling up clean all dust and dirty from the grease nipples and other parts which are needed to lubricated
63. ion Leaf Spring Thickness mm Amount of piece leaf spring Main spring 7 3 Auxiliary spring 14 2 Static deflection S 101 Length L mm 1200 Width mm 70 Shock Absorber Work length mm Min Max 338 548 Jouney mm 210 Damp N Extend Compress 2250 350 600 130 Diameter mm A B 54 45 Check and adjust Bearing of wheel Side clearance of wheel bearing mm 0 02 0 15 Thickness of side gascket of rear axle mm 0 05 0 07 0 10 0 15 0 20 0 50 1 00 Tightne torque of bearing locking nut N m 167 196 Tightne torque after loose the bearing locking nut N m 167 196 Start torque of turning the wheel bearing N m 2 1 3 4 Bolt of nub N 24 5 40 2 RA 13 Rear Axle amp Rear Suspension Profeller Shaft and Differential PD Catalog Preperati Ostet cena teaicca leant a EAE a aualeds PD 1 Profeller Shaft sacicsrtnueee ois st niian iat e EEE Ta aet PD 4 Mai tainance errea aaee a E E T E PD 9 Disassembly and ASSeMDILY cccccccceceessscceececcsseseseeeeeeeeeeeees PD 10 Mam RECUCER fics aster ty cecil nyi one a el cet a EE Sh PD 11 Disassembly arria eioten Eaa twine len I EEEE EE E REER PD 12 Checkiaee snae e e E saat eae ceataletls PD 17 Ad ae eA a T a S tates PD 18 ASSEMDlY an rena aa aa aa re eai i PD 19 Profeller Shaft and Differential Preperation nut Special Tool 1 Differential fixing assistant tool 1 Engine bracket 2 Seat 2 Differential assistant to
64. ith supporting battery and the cable if necessary please use 12 V auxiliary battery After connecting the battery cable make sure their connection with the joints is well How to maintain the battery Method of preventing over discharge The following precautions must be taken to prevent the battery over discharge Keep clean and dry 1 The battery surface partticularly its top should always be kept clean and dry If there is electrolyte or water on the top it will cause the battery to discharge Remove negative terminal 2 If the vehicle no used for quite long time release off the negative pole joint EL 2 Electric System 3 Check the condition of battery charge Check the proportion of electrolyte periodically carefully watch the charge state to prevent over charging Liquid level check Warning Do not let the electrolyte touch with your skin eyes and painted surface After touching the battery you must clean your hands thoroughly If acid liquid goes into your eyes skin and cloth wash them right away with clean water for 15 minutes and seek some medical attention Normally the battery does not need to add water but under bad condition steamed water needs to be added 1 Release off the battery plug with proper tools 2 Add in steamed water until max Sulphation If battery is not maintained for a long time the proportion of electro lyte is lower than 1 00 and the battery is totally discharged
65. ixed bolt 25 35 Fan fixed bolt 7 9 Push lever nut of brake thruster 16 22 As for the other torques not mentioned please see the standard of DONGFENG EQB 37 1999 Note No locking spacer but to make sure the required tightening torque When tightening during installing make use of the oil to lubricate Do not use the bolt with thread damaged Each bolt need to tighten within 2 3 times GL 12 Clutch TOC Precaution and Preparation cccccccccccscscsscscscsecsssesecscscseescseseeseseeeees CL 1 EIEE SY SteMiie a a re ne EN ele le CL 3 Clutch Control SysteM cae a ec casa nace baa uecenees era aero a arenes CL 4 Clutch Release Mechanism ccccccccsesccecsesecseseseeseseseeseseeeeeseneeeees CL 6 Clutch Driven Disc and Pressure Plate ccc eceeeseseeeteneeeeee CL 7 Service Data and Specifications soecs2 cccccscc2scaacencetescacabicectettadendatsicess tact CL 9 Clutch Clutch Precaution and Preparation Precaution The DOT 4 901 4 compound brake fluid is recommended for the clutch hydraulic system Dirty brake fluid is forbidden to use Never let the brake fluid on paint it may damage the paint coat Use tools to assemble or disassemble the clutch pipeline Use clean brake fluid to clean the master cylinder slave clinder and fluid reservoir Forbidden to use mineral oil like gasoline coal oil etc it will erode the rubber parts in the hydraulic system Note After clean the clutch pressure di
66. l duct 24 Spring washer 25 Cross recessed flat round head screw ST 6 26 Duct clip 27 Steering screw lever 28 Cylinder pin 29 0 rubber sealing ring 30 Torsion bar 31 Valve pocket 32 Needle bearing 33 Cylinder pin 34 Imput shaft 35 Cylnder pin 36 Steel ball 37 Outside ring 38 Sealing ring 39 0 rubber sealing ring 40 0 rubber sealing ring 41 Valve body 42 Big cone joint 43 Circlip for holes 44 Single annular ball bearing 45 Oil seal 46 0 rubber sealing ring 47 Upper cover 48 Retainer nut 49 Dust cap Steering System Steering Tie rod Disassembly and assembly 26 9 YY at y E N NI OMe X Y Nw X amp Ws D DA O m a moe NN Deon 20 Ko oN ars a i Hae aN S 1 Remove the cotter pin and nut from the tie rod connecting 2 Q Z ax fe g O O N O T H S Q O n pus Q gt H o Q g a a O n 5 O avi ori g O S E S 2 isc a Q o D E G z pmi low ST 7 Steering System 2 Make use of proper tool to release the ball pin connection part like connecting pull rod etc 3 Remove the drag link from the steeringdrop arm by use of tools Side pull lever 4 Remove the fixed bolt of front and rear limit bracket Intermediate pull rod and tie rod 1 When disassemble the tir rod ball head connection adjust the pull rod length
67. ll Battery connecting wire not connected well Brush wore and not well connected Magnetic switch coil cut and short circuited or earthed Flexible core of magnetic switch blocked Motor with weak running Battery charging not well Motor not well installed with some mechanical break downs Rectifier dirty or damaged Starter idling Single directed clutch sliding Battery connecting wire not well connected Brush worn and spring tension reduced Armature coil cut circuit somewhere Drive gears not well teeth Motor not stopping Ignition switch blocked touching point not disconnected Magnetic switch main touching point burned and sticked Starting relay touching point not disconnected Flying wheel gear ring and drive gear rough and sticked EL 5 Electric System Combined Switches Replacement It is not necessary to dismount the combined switch base while replacing each switch Wiper and washer switch When dismount the combined switches first dismount the connecting bolts Front Head Lights Bulb replacement The front head light is half sealed using a replaceable halogen osram lamp The lamp can be replaced from the inner end without releasing off the whole head light assembly Bulb cover Hold the plastic bracket while replacing do not touch the glass cover 1 Release off the connecting wire harness from the rear end 2 Turn the bulb anti clockwise until it loose and off 3 Open the rub
68. ll pin Capacity Data Fuel tank Synthetic brake liquid Li base lubricant grease 901 4 Capacity L 65 SH0535 93 Engine lubricant system 6 5 Water tank and cooling system 13 to full Transmission 2 7 Main reductor 6 5 5 0 to overflow to the MAX GL 8 to the MAX General Fuel The qualified light diesel oil specified by GB T 19147 2003 could be applied for in China and the users choose different qualified light diesel oil according to the local temperature O Light diesel oil 10 Light diesel oil 20 Light diesel oil 35 Light diesel oil 50 Light diesel oil Local temperature above 4 C Local temperature above 5 C Local temperature between 5 C 14 C Local temperature between 14 C 29 C Local temperature between 29 C 44 C As for the vehicle for export please take the local national regulations and standards and the cli mate for reference to choose the proper diesel oil Engine Lubricant API CF 4 Grade diesel oil or special oil for CYQD32 is recommended According to the local air temperature the user may choose different CF oil with different viscosity grade Recommended tem perature range is as below Gear Oil 40 30 20 15 M E E 20W 40 20W 50 15W 40 15W 50 Middle load API GL 4 gear oil heavy load GL 5 gear oil is recommended The recommended ambient temperature range for all gear oil
69. lower ball head pin clamp nut 2 Dismount the steering knuckle from the upper and lower ball head connecting part by special tool Never screw off the loose nut in step 1 3 Screw off thelock nut of ball head pin and lift the lower transverse arm by the jack 4 Dismount the steering knuckle from the upper and lower transverse arm FA 14 Front suspension Inspection Steering knuckle Check the steering knuckle for any defprm crack or damages by the method of magnetic test Assembly Use the jack to lift the lower transverse arm and install the upper and lower ball head pin and the steering knuckle Note Never let the grease on the steeing knuckle tapered face and the thread and tapered face of the upper and lower ball head pin assembly During the assembling process do not damage the dustproof of the ball head pin After assembly the steering knuckle adjust the hub bearing pretightening force See chapter Hub amp brake disc to be the reference o fhe adjustment of pretightening force FA 15 Front Independent Suspension Front suspension 23 Cm 1 Shock absorber assy 2 Upper arm shaft 3 Inner side washer 4 Rubber bush assy 5 Big washer 6 Upper transverse arm 7 Bolt 8 Round head pin assy 9 Front suspension cross member assy 10 Circlip for holes 11 Torsion bar adjusting arm 12 Adjust bolt 13 Round head 14 Front torsion bar spring 15 Torsion bar fixing bar 16 Lower
70. ly 19 Thrust washer MT 14 Transmission Reassembling of shifter cover assembly Assembling sequence 1 0il seal 2 Speed selective shaft sets 3 Speed selective shaft internal rocker arm 4 Flat washer 5 Speed selective shaft reverse stop spring 6 Flat wasger 7 Elastic pin 8 Oil seal 9 Flat washer 10 Speed selective shaft sets 11 Speed selective shaft external rocker arm sets 12 Elastic pin sets 13 Backing light switch MT 15 Transmission Reassembling and specifications for transmission assembly Assembling sequence 1 Countershaft 2 Countershaft 5th speed gear Put the countershaft assembly and Sth speed gear together and mount them into the case with the 5th speed gear close to the rear end 3 Reverse shaft gear assembly When assembling be sure that the longer end of reverse shaft gear hub faces forward and then insert the reverse shaft pin MT 16 Transmission 4 Reverse shaft 5 Reverse shaft stop pin 6 PTO Coverplate 7 Connecting bolt 6 8 grade 8 2nd shaft assembly 9 Centripetal ball bearing the rear of 2nd shaft 10 1st shaft assembly First measure the distance x between the front end face of synchro nizer gear hub 3rd speed 4th speed and the front end face of housing When the value of X is less than 53 85mm mount Ist shaft centripe tal ball bearing first then install Ist shaft shim and retainer ring in sequence Front end face of housing When
71. narsideaueaetoenis GL 10 General General This manual mainly contains maintenance and service method of the DONGFENG STAR EQ1030T47D 820 light commercial truck DONGFENG STAR Engine Equip EQ1030T47D 820 CYQD32 diesel COE single row with front independent suspension engine power steering front disc and rear drum brake To use vehicles safely and efficiently it is important for you to read the manual thoroughly and make sure that you are familiar with the items that mark Note Due to continuous improvements on our vehicles maybe there are some instructions in the manual that does not compliance with the actual vehicles Please consult the local agency for the latest news The informaion in this manual are correct before issuance DONGFENG reserve the rights of changing any of the content without notice Maintenance method varified due to different skill level method tools and available parts that serviceman adopts to Any serviceman should firstly take into consideration on personal safety and vehicle safety when working The Application File Section of Test Department the Commercial Product R amp D Institute of DONGFENG AUTOMOBILE CO LTD is in charge of compiling 2006 6 GL 1 General Preventive Measures See preventive measures below to get safe operation and suitable mainte nance surely These measures will not be repeated in the next pages 1 Do not let engine run too long absolutely unles
72. nection Disassemble the steering arm Pulling tools steering arm spanner Lock nut wrench Adjusting and tightening the lock nut Spanner adjusting screw Measuring the torque Torque spanner om D q ST 1 Steering System Tool Name Brief Description Installing the steering gear on it Accessories bracket and steering gear casing Adjusting the preload of worm bearing Torque connecting end Check with the Vehicle Check the free play of the steering wheel e Measure the free play when steering wheel is in central position driving straight Free Play Value lt 35mm eIf not within this value check whether the gear clearance and rod ball pin of steering gear for any loose Check the central position of the steering wheel e Before disassembling the steering wheel calibrate the central position of the steering wheel Check e Check whether the steering wheel is in the central position when driving straight e If not disassemble the steering wheel and reassemble it again e If the central position is just between two fine gears release the lock nut of tie rod and move the rod reversal at the same distance both on the left and right to compensate the difference of the central position Check turning Angle of the Front wheel e Turning the steering wheel to on both left and right extreme to measure the turning angle of the front wheel Inner whe
73. nsion Thickness of the adjusting spacer 1 0mm 1 6mm 3 2mm Don t use more than 3 spacers in the same place When assemble the spacer insert from top to bottom The total thickness of the spacer should not be more than 9 6mm The thickness difference of the same side of the front and rear end should not be more than 4 8mm Follow the below steps to confirm the needed spacer thickness of adjusting wheel camber and caster 1 Respectively increase the adjusting spacer of Imm thickness at the same side front and rear end and then the wheel camber angle of this side will reduce 0 15 while the caster will not change 2 If the front end is Imm more than the rear end adjusting spacer of the same side the caster angle of this side will reduce 0 24 while the camber angle will reduce 0 7 30 3 If the front end is Imm less than the rear end adjusting spacer of the same side the caster angle of this side will increase 0 24 while the camber angle will increase 0 7 30 4 1f the wheel alignment parameter is still incorrect after the adjustment of above the frame has to be adjusted Toe in 1 Mark a reference line on the tyre make the vehicle front part on the ground and shock it up and down for several times to eliminate the clearance and then set the steering wheel to the position of front straight driving 2 Measure the toe in Measure A and B at the wheel midline in the same height Toe in value tek chs K Toein
74. ock arm of transmission is pushed in position or dismount the transmission cover and push the fork by hand to engage the gear 1 Wear of fork shaft circular groove check the engagement condition and interlock pin plastic deforma 2 If not completely engaged check the fork for 1 The transmission tion of lock ball spring deformation or overwear of working suface Dis ngagem nt shifts into neutral 2 Wear of fork working surface 3 If the gear sleeve is completely engaged automatically during 3 Wear of connecting cone for syn check the gear sleeve and the back taper part of driving chronizer toothed ring and gear connecting tooth for wear sleeve 4 If the clearance is too large when stirring the 4 Axial looseness of gear fork check the fork shaft groove to see whether the locating spring is worn or faulty 5 Check the 2nd shaft nut of tightening flange for looseness if so the axial position of 2nd shaft gear will change MT 1 Trouble Phenomenon Transmission Probable case Judgement amp Trouble shooting The gear couldn t be engaged prop erly 1 Without the failure of clutch shifting is difficult with serious pound or disengage ment at some gear is hard 1 Severe wear of interlock pin 2 The fork head of internal speed selective rocker arm is sevrely worn or damaged or separate from shifter small rocker arm groove 1 Check the faulty area and remove the failure Noise
75. ol Assembly driving axle 3 Flange spanner Disassembly and assembly driving axle locking nut and drive gear locking 4 Differential bearing adjusting nut spanner Adjust bearing preload and tooth sapce 5 Differential bearing adjusting nut spanner 6 Differential bearing adjusting nut spanner 7 Drive wimble gear assembly gauge yp 1 Model shaft Q D 2 Height gauge CKA Select gear height adjusting gasket Profeller Shaft and Differential 8 Drive wimble gear assembly gauge 1 Height gauge 2 Model shaft esr S 9 Drive wimble gear assembly gauge 1 Height gauge 2 Tightening clincher A 10 Drive wimble gear inside track tension seat 1 Tension implement 2 Seat Disassembly and assembly drive bearing rear taper bearing B 11 Preload testing gauge 1 Torque spanner 2 Inserted joint of 3 Inserted joint Teat gear bearing preload and total preload 3 12 Differential bearing tension implement seat 1 Tension implement 2 Joint Disassembly and assembly drive bearing inside taper bearing 13 Weight block Select bearing adjusting gasket PD 2 Profeller Shaft and Differential 14 Revise gauge Select bearing adjusting gasket 15 Differential bearing punch Assembly inside taper bearing 16 Punch Assembly rear bearing sleeve 17 Punch B Assembly front bearing sleeve 18 Punch B Assembly rear bearing sleeve O 19 Bearing seat punch A
76. out 1 Use a nylon pipe to connect the exhaust valve 2 Depress the pedal to the end several times 3 Maintain the pedal at the end loosen the valve to exhaust 4 Tighten the exhaust valve 5 Release off the pedal slowly 6 Repeat the 2 5 steps until pure liquid flowing out of the exhaust pipe Exhaust following the steps below Left rear wheel right rear wheel left front wheel gt right front wheel BR 3 Brake Pipe Brake System 1 0il brake pipe assy 2 Oil brake pipe assy 3 Three line straight joint 4 Oil brake pipe assy 5 1st oil brake pipe assy 6 Three way joint 7 Front three way bracket assy 8 0il brake pipe assy 9 Oil brake pipe assy 10 Pipe clip for three pipe inline 11 Shim 12 Brake hose assy 13 Straight joint 14 Single pipe clip 15 2nd oil brake pipe assy 16 Brake hose assy 17 0il brake hose assy 18 Oil brake hose assy 19 Nylon bush 20 Bracket 21 Upper bracket 22 Three pipes clip BR 4 Brake System Disassembly Note Be careful not spray the brake liquid on the painted area otherwise it will damage the painting surface if it dose clean it immediately with clean water Avoid bending twisting and stretching of all the hoses too much when disassembling 1 Use a nylon pipe to connect the exhaust valve 2 Depress the pedal several times to exhaust all the liquid out of the valve 3 Loosen the nut of the hose mouth connected with the brake 4 Whenev
77. pin use a new one ST 9 Ball head pin AD 4 B Ball head pin cS B Rubber bush Dust proof SST670A Steering System Power Steering System 1 Steering oil pump assy 10 Steering gear oil intake hose assy 2 Steering oil pump bracket 11 Straight joint 3 Bolt 12 Throat hoop 4 Bolt 13 Dual pipe clip upper bracket 5 Oil reservoir assy 14 Steel pipe clip backing ring 6 Oil pump intake pipe assy 15 Steering gear oil intake pipe assy 7 Clip 16 Steering gear oil return pipe assy 8 Adjustable elbow joint assy 17 Power steering gear assy 9 Rubber hose ST 10 Steering System Maintenance Data and Explanation Basic parameter Steering gear drive ratio 23 26 Steering wheel turning circle 4 3 Check and adjust Steering wheel Steering wheel axial clearance mm 0 Steering wheel free travel mm 10 40 Steering column Steering column length L mm 484 Connecting rod mechanism Ball head pin assy Transverse swing force measuring point cotter pin N Drag link tie rod intermediate pull rod 5 9 64 7 Driving moment N m Drag link tie rod intermediate pull rod 0 3 3 4 Axial clearance mm Drag link tie rod intermediate pull rod 0 Tie rod standard length L mm 664 5 ST 11 Steering System ST 12 Brake System BR TOC AttentionS 5c isco esincctdsanceria 5s detandisacaa bvas Suhcnan Guntonct saeesbbanes ie endetacas abibaiteicevateseeae BR 1 Checkand Ad ust 40 ale eae Li Oo fen a BR
78. pproch Increase the thickness of the gasket of drive gear to close it to driven gear B Adjust approch Decrease the thickness of the gasket of drive gear to keep away it from driven gear After adjusting wipe up the ferric oxide Big end contact Top contact Small end contact Bottom contact ee W a Le PD 18 Profeller Shaft and Differential Assembly Differential Housing 1 Assembly gear of half shaft planetary gear plane tary gear set and thrust spacer 2 Incert the planetary gaer shaf into differential hous ing and contact it to the hole of locking pin 3 Select thrust spacer of half shaft gear and adjust clearance between the back side of half shaft and thrust spacer Thicknees Gauge Thickness Gaugq 4 Assembly the locking pin of planetary gear by punch PD 19 Profeller Shaft and Differential 5 Put gear oil on the surface of gear and check the running situation of gear Gear Oil 6 Put seal glue on differential housing and the surface of driven gear s contact area then put the differential hous ing on the main reducer driven gear 7 Put seal glue on the bolt of driven gear 8 Assembly new locking spacer and bolt Screw down bolt by tool and knock the head of bolt by hammer softly Bend the locking spacer to lock the bolt in the tight position 9 Assembly the inner taper of half shaft bearing on differential housing by tool PD 20 Profeller Shaft and D
79. rce of the suspension parts 7 Measure the vehicle gesture H H A B mm no load See Maintenance data amp explanation for reference FA 19 Front suspension 1 Shock vehicle front part up and down for 4 5 times to make the vehicle gesture is in correct height 2 Measure the vehicle gesture value H See Wheel alignment of Maintenance data amp explanation 3 If the H is different from the required value adjust the vehicle gesture See Wheel alignment of Maintenance data amp explanation 4 Check the front wheel alignment if necessary See Wheel alignment of Maintenance data amp explanation 8 If the H value is not in the required range adjust the adjusting nut of the adjusting arm to assure the correct vehicle gesture Upper transverse arm Disassembly Disassemble the fixed nut of the lower shock absorber Disassemble the connecting bolt of the upper ball head pin and upper transverse arm Lift the lower transverse arm by jack Dismount the fixed bolt of the upper transverse arm shaft Assembly When tightening the upper transverse arm shaft make use of some adjusting spacer of the wheel camber FA 20 Front suspension Check the A and B dimension after tightening A 110mm B 32mm Assemble the upper ball head pin on the upper transverse arm Assemble the upper fixed nut of the shock absorber Tighten the upper transverse arm locking nut under the condition of wheel
80. reful not smash the painted surface of the truck GL 2 General 7 Before the check and assembly of a disassembled part clean it first 8 During the reassembling oil seal gasket O washer lock washer and split pin should use the new one 9 Replace the outer and inner rings of tapered roller bearing in whole set 10 Arrange the disassembling procedures according to the part assembling order 11 Mark on the disassembled brake pipe about the connecting relationship 12 Use suitable lubricating oil brake fluid cooling liquid and seal glue according to standard 13 Use general and special tools to ensure maintenance safely and effi ciently 14 Deal properly with drained lubricating oil and solvent used to wash parts How to Use Manual 1 Look up contents as quickly as possible The contents of every section are completely listed on the first page of each chapter 2 The subject of each chapter is on the top of every page showing the name of each system of assembly 3 The page code of each chapter is of two or three letters to show the name and page code of a certain chapter ex BR 5 4 A larger diagram is used to show the separated construction of an assem bly its contents tightening torque lubricating points and the other information for maintenance These are dor the reference of mainte nance and you have to see the SPARE PARTS CATALOG for parts booking 5 The smaller diagram mainly indicate ever
81. s Q ACCEPTABLE RANGE Electric System Windshield Washer and Wiper Disassembly of wiper Before disassembling turn off the wiper switch Disassembly Disassemble the wiper arm Disassemble the lock nuts washer and seal rubber shim Disassemble the instrument assembly Disassemble the left and right guide pipe and ventilating pipe Prize the wiper connecting rod off the motor arm with a screw driver Note Be careful not to destroy the wiper connecting rod while disassembling Disassemble wiper motor to amplifier harness connector Disassemble the bolts on the wiper motor bracket Disassemble the motor arm Disassemble the wiper motor from the installation bracket Disassemble the wiper intermittent relay from the bracket Disassemble the wiper connecting rod Installation When installing proceed the above procedures reversedly The wiper must be adjusted after installation Adjustment Before installing the wiper arm first the wiper motor then turn it off automatic stop Raise up the wiper brush then place it on the surface of window glass right away to make the brush center on the location between c and d then tighten the nuts Spray some cleanser start the wiper motor and then switch it off Assure to make the wiper brush on C and D position and then tighten wiper arm nuts to its specified torque Standard cab C 45 55mm D 45 55mm EL 8 N Wiper motor bracket
82. s it is under special venti lation to ensure that there is good ventilation in working area no fire things there Be careful sternly the any burnable poisonous things like gasoline refrig erant etc are used Working in a ditch or close environment and contacting any dangerous things it is necessary any dangerous things it is necessary to provide good ventilation in the working area and smoking is prohibited there absolutely 2 When truck is lifted use a wheel stationary block to stop the truck move After lifted used a safe mat to support the truck on a specially designed point of truck to bear the truck weight then begin its maintenance These operations should be completed on an even ground 3 Being unfixed a heavier assembly like engine gear box or rear axle be careful to keep it balance avoid it fall down And not permit to damage the details next to the brake pipes etc 4 Working at some maintenance without battery turn off the ignition switch and power switch at first and then take off the negative line on the battery to avoid unexpected accident happening like short circuit 5 To prevent serious burnt accident avoid touching some hot metal such as radiator exhaust manifold and muffler etc When a engine is hot do not take off the lid of radiator absolutely 6 Before maintenance use the suitable cloth to cover the inner ornaments and ground mat of the truck in order to keep it in a good condition Note Be ca
83. s ula eS el natalie ST 2 Steering Wheel and Steering Column cceceeeeeseseeseeteeeesens ST 3 BlCenine Geal aicis nc cceuiesais eared aes Miers at cae Soc galas ST 6 Steenin cee G66 SRR ee nee OY eae cr re E E mea One ee ere ST 7 Power StCGTIiN O S VSCCI gcceteces cota es cor rcnce stirs Needed beat cuter eaaettacati ted ST 10 Maintenance Data and Explanation cccccceseeeeeeteeeeteeeeeees ST 11 Steering System Steering System Notes e Before disassembling please clean external surface of the parts carefully e Disassemble the parts in a clean working area to prevent any dirt and other objects from entering e Put the disassembled parts in order for later reassembling e Clean the parts by using nylon or soft paper normal shop cloth will cause some remains on the parts to interfere the movement e Before check or assembly clean all the parts carefully with liquid e Before assembly it is better to apply a layer of oil used for auto transmission on the surface of hydraulic parts and apply a layer of vaseline on the O type oil seal instead of lithium lubricanting grease e Replace all the washers oil sealing and O type rings to avoid using damaged washers oil sealing and O type rings in assembling After the assembly proceed a test run for property Special Maintenance Tools Tool Name Brief Description Pulling tools steering wheel Ball connection separator Disassemble the steering wheel Release the ball con
84. sc Check whether the driven disc has been burnt discolored or polluted with Facing runout oil or grease Change it if necessary Spline backlash Assembling Apply some grease on the connecting surfaces and spring Note Most grease might result in damage to the driven disc surface Clutch Pressure Plate and Flywheel Checking and adjustment e Check the height and unevenness of diaphragm spring Put the feeler T 0 2 on the space bush during checking up the height of the diaphragm spring Height of the diaphragm spring 41 43mm If the height of the diaphragm spring is measure beyond the set range change the pressure plate surely Check the worn or damage condition for the diaphragm spring support washer by rocking the pressure plate by listening to the vibration sound Judge whether there is light crackle sound by patting the rivet gently Change the pressure plate if necessary e Check whether the pressure surface of the pressure plate is burnt or dirt ied Remedy it with the emery paper CL 8 Clutch eCheck whether the matching surface of the pressure plate and driven disc has deformation or damage Change them if necessary e Adjust the unevenness of the diaphragm spring with tool Wrench for adjusting Flywheel check eCheck whether the working surface of the flywheel is burnt or discolored Remedy it with the emery paper Flywneel Check its surface for planeness Dial indicator Clutch co
85. sc use the dust collector to clean the dirt not the compressed air Preparation Specified tools Base dice Bush Connecting nut spanner Clutch mandrel Diaphragm spring adjusting spanner Bearing detacher CL 1 Use for checking the diaphragm spring of clutch cover Use for examine the life of pressure plate Disassemble and assemble the pipeline of clutch system Use for assembling clutch housing and clutch disc for center Use for adjusting the evenness of the clutch diaphragms spring Use for dismantling the release bearing Clutch Clutch System 1 Clutch pedal bracket assy 9 Dustproof 2 Rubber hose assy oil reservoir to master pump 10 Front oil pipe assy 3 Clutch master pump assy 11 Spacer 4 Clutch pedal welding assy 12 Rear oil pipe assy 5 Pedal jacket 13 Clutch rear bent pipe bracket 6 Clutch pedal shaft 14 Hose assy 7 Clutch pedal return spring 15 Gasket 8 Lower fixed board 16 Clutch slave pump assy CL 2 Clutch Adjusting Clutch Pedal 1 Adjust the pedal height by means the spacing screw Clevis pin Height of the clutch pedal H 160 170mm 2 Adjust the clutch pedal free play by master cylinder push rod Loose the locking nut when adjusting turn the master cylinder push rod then make the push rod withstand the spacer and screw off for 1 5 1 2 cir cles screw down the locking nut at last Pedal free play A 30 50mm Bleeding Procedure Bleed air accord
86. se speed All the forward speeds are synchromeshed Sth speed is overdrive gear All of them apply skew cylindrical gear engagement and the gear shifting is smooth Gear ratio Ist speed 2nd speed 3rd speed 4th speed 5th speed Reverse speed 5 016 2 672 1 585 1 000 4 783 Odometer ratio 14 4 lubricating oil Brand Manual transmission oil LAN 1 85W 90 or engine oil SAE 5W 30 Oil volume 2 7L Service and Maintenance Notes for Transmission 1 Add lubricating oil as specified before mounting the transmission on the vehicle 2 During shifting operation depress the clutch pedal to the bottom Before shifting into the reverse speed stop the vehicle completely 3 When crossing a river or operating in mud prevent water form entering into the transmission Otherwise oil must be replaced 4 The Service and maintenance of transmission shall follow the service and maintenance instructions for light duty vehicles Replace the lubricating oil of transmission periodically When replacing the oil loosen the oil drain plug at the lower part of transmission housing After draining the oil in the housing tighten the oil drain plug Fill the lubricating oil into the transmission through the filling plug port on transmission shifting cover until it reaches the lower edge of filler port Trouble and Troubleshooting Trouble Phenomenon Probable case Judgement amp Trouble shooting 1 Check the operating system to see whether the shifter r
87. shaft by tool PD 13 Profeller Shaft and Differential 5 Disassembly differential housing ass y by a tommy bar Pay attention that seperate the outside track of bearing and taper in right and left respectively in order not to mis tacken them 6 Diassembly nut of drive conic gear by tool 7 Disassemby connecting flange by tension imple ment PD 14 Profeller Shaft and Differential 8 Take off drive conic gear its rear inner conic bear ing bearing seat and adjusting gasket of bearing together 9 Disassembly front oil seal and front conic bearing 10 Disassembly outside track of gear bearing by a brass stick 11 Disassembly inner conic bearing of drive conic gear and adjusting gasket Differential Housing 1 Disassembly inner conic bearing of half shaft Pay attention not to damage bearing or engaging key PD 15 Profeller Shaft and Differential Pay attention not to mistake left and right bering parts 2 Loose bolt of driven gear by tool 3 Knock driven gear by soft harmmer then disassem bly the gear from differential housing 4 Take off cross locking pin from the side of driven gear by punch 5 Disassembly differential housing and mark on left and right differential housing PD 16 Profeller Shaft and Differential Check Driven Gear and Drive Gear Check whether there are any nicks cracks or chippings if there are some obvious damage must replace the gears
88. speed 5 Synchronizer assembly 1st 2nd speed Mount it non directional select and fit the thickest snap ring Non direction Provided thickness mm 1 75 1 825 1 875 ey i a ath MT 13 Transmission 6 Synchronizer gear ring 1st 2nd speed 7 2nd shaft 2nd speed gear 8 Thrust washer and retainer ring After assembling measure the distance X and select the fittest retainer ring from the table below Distance X Retainer ring thickness mm 2 20 2 27 1 875 2 27 2 32 1 925 2 32 2 37 1 975 2 37 2 43 2 025 9 2nd shaft 3rd speed gear and needle bearing 3rd speed 10 Synchronizer gear ring 3rd 4th speed 11 Synchronizer assembly 3rd 4th speed Foriara The sliding block is non directional place the synchronizer gear fi sleeve with its groove facing the 3rd speed gear and the synchronizer gear hub with its big end facing backward select and mount the thickest retainer ring Provided thickness mm 1 775 1 825 1 875 12 Synchronizer gear ring 3rd 4th speed Non diection Big fillet 13 Needle bearing reverse 14 2nd shaft reverse gear 15 Synchronizer assembly reverse Sth speed Forward The synchronizer gear hub face with bigger basal plane must face the reverse gear the front for transmission select and fit the thickest retainer ring Provided thickness mm 1 775 1 825 1 875 Non direction 16 Synchronizer gear ring 5th speed 17 Retainer ring 18 2nd shaft 5th speed gear assemb
89. ss y Steering System e Install the spring lock ring on the upper shaft with tools Steering Lock a Remove the lock screw with a clamp b Tightening the lock screw Notes Pay attention to whether the position of the steering lock mechanism is correctly located Adjusting the Mechanism e After installing the steering column check the movement of the adjusting mechanism Front Rear L1 15mm L2 45mm Upper Lower L3 10mm L4 20mm Check e If the steering wheel could not turn smoothly check the steering column from the following aspects and replace relevant damaged parts Check whether bearing of the steering column is damaged or uneven lubricate it with recommended common grease If necessary replace the steering column assembly Check whether the sleeve is deformed or damaged replace it if necessary If the vehicle is hit a little check the dimension of L If the L value is ont in the required range replace the steering column L 484mm ST 5 Steering Gear Steering System 1 Hex neck bolt 2 Spring washer 3 Hex nut 4 Side cover 5 0 rubber sealing ring 6 Retaining nut 7 Adjusting bolt 8 Retaining ring 9 High pressure sealing ring 10 Needle bearing 11 Steering arm shaft 12 Cone plug 13 Housing 14 0 rubber sealing ring 15 Dustproof 16 Spring washer 17 Hex thin nut 18 Casing cap 19 Sealing ring 20 0 rubber sealing ring 21 Steering nut 22 Steel ball 23 Steel bal
90. ssembly bearing seat A 20 Bearing punch Assemble taper inside bearing 21 Bearing seat front oil seal punch Assembly front oil seal Profeller Shaft and Differential Profeller Shaft Maintain of theVehicle Vibration on Profeller shaft If profeller shaft vibrates when the vehicle is in high speed check the diameter run out of the shaft first Lift rear axle 2 Turn profeller shaft and check the diameter run out amount of a certain point on it Measure point of profeller shaft mm A 155 B 165 Cross shaft C 185 PD 4 Profeller Shaft and Differential 3 If diameter run out amount exceeds the limited value turn the connecting flange of the rear axle s one end for 180 degree then assembly the profeller shaft Diameter run out amount refers to Maintainance data and Explaination 4 Check diameter run out amount again if it still exceeds the limited value replace a new profeller shaft 5 Road test Check the Appearance Check weather there are any cracks or sucken holes on the surface of profeller shaft Replace the shaft when there are any ones Disassembly and Assembly Mark the flange set then disassemble the profeller shaft from rear axle s end Pull the profeller shaft out of transmssion system and Slip fork fill in it with a plug Check Ckeck the diameter run out amount of profeller shaft if it exceeds the limited value replace the shaft PD 5
91. the pressure change of the battery is not over 0 05 V h within 2 hours at the end of charging period the proportion of electrolyte does not change obviously also taking temperature into consider ation then the battery can be regarded as fully charged During the whole charging period the temperature of elec trolyte should be maintained around 20 40 C taking the middle single battery measuring value as standard Charging per fixed pressure Use fixed pressure 14 80 0 05V for charging the max current should not be over 30A During the initial charging period if the current is over this number the pressure is allowed to reduce properly If the pressure change of the battery is not over 0 1A h within 2 hours at the end of charging period the proportion of the electro lyte does not change obviously also taking temperature into consideration then the battery can be regarded as fully charged During the whole charging period the temperature of electrolyte should be maintained around 20 40 C taking the middle single battery measuring value as standard When there is a lot of bubbles coming out of the battery and the pressure is stable at the end of charging the proportion and the height of the electrolyte should be adjusted to their specified value The electrolyte proportion of a fully charged battery is 1 28 0 01 at 25 C Charging System Note When installing the battery be careful to make the earth pole of the battery same as the engine
92. the protruding part of the lock washer RA 5 Rear Axle amp Rear Suspension 7 Remove the bearing lock nut by special tool Special tool ee 8 Disassemble the wheel bearing bearing cover and splash guard from the half axle Special tool 9 Disassemble the grease seal ring from the bearing cover by a proper lever 10 Use a brass bar to disassemble the outer ring of the wheel bearing RA 6 Rear Axle amp Rear Suspension Check Half axle Check the half axle for any bend crack damage wear or distort replace if necessary Wheel bearing Make sure if the bearing drive freely without noise crack notch or wear Rear axle housing Check the rear axle housing for distort or crack replace if necessary Assembly 1 Make use of the proper tool to install the wheel bearing outer ring 2 Install a new grease seal ring in the bearing cover Bearing outer ring After installing the new seal ring wipe some li based grase on the edge of the seal ring 3 Make use of a copper bar to install the bearing inner ring Smear some li based grease on every conic bearing ring 4 Assemble the flat spacer and a new bearing lock washer 5 Use tool to tighten the bearing lock nut Tighten the lock nut to make the bearing lock washer edge in the proper groove of the bearing lock nut and then make the edge upwarping 6 Assemble a new oil seal by the proper tool After assembling the new oil seal smear some
93. together Differntial Housing Ass y Check the assembly surface of differential hous ing bearing of half shaft planetary gear shaft of planetary gear and thrust washer Bearing 1 Wash bearing completely 2 Check the abrasion scratch hole or scall off situa tion of bearing Check the drive agility of conic rolling bearing If there are any damage replace outside track of bearing and inner taper together PD 17 Profeller Shaft and Differential Adjusting Gear Contact Area To proof whether the driven conic gear and drive conic gear mesh correctly the shape of contact area should be checked If the hyperbola gear mesh mesh incorrectly it will cause noise and shorten the duration of the gears By checking the shape of contact area and adjust the gears to their best meshing position it will reduce noise and increase the duration of the gears 1 Wash the gears of driven conic gear and drive conic gear completely 2 Select 3 4 gears of driven gear which are near drive gear and wipe a flat of ferric oxide 3 Turn connecting flange by hand to turn driven conic gear positive and negative If the caculated clearance value and the thickness are correct the shape of gear contact area will be normal But generally because of the wrong shape of contact area it has to repeat the mentioned process above until adjuting to the correct way Several shapes of gear contact area and adjust approches are showed A Adjust a
94. ver and flywheel When assemble the clutch pressure plate and driven disc insert the special tool into the spline hole of the driven disc using for central position Tighten the fixed bolts the clutch cover Tighten the bolts as cross procedure shown in the figure with two steps Clutch cover Service Data and Specifications Clutch driven disc Outside diameter 260mm Thickness 8 0 0 3mm Checking and adjusting Pedal height 160 170 Pedal free travel 30 50mm The datum measured is referred to distance between the floor surface and the pedal Clutch driven disc Wear limit form the friction surface to the rivet head poem Effective thickness of the friction lining 1 2mm Nominal size Clutch pressure plate Diaphragm spring height 41 43mm CL 9 Clutch CL 10 Transmission TOC Technical Performance OvervieW ou ccc ceccecesscesscesccescssceseceseenseeaeeens MT 1 Service and Maintenance Notes for Transmission 0 ccceeceeeeeee MT 1 Trouble and Troubleshooting c ccc ceccceesececseseeeesesesecseseeesseseeeees MT 1 Disassembling Procedures and Notes for Transmission Assembly MT 2 Check and Re palit Acorns anes aucune nai m ER A MT 11 Reassembling Procedures and Notes for Transmission AssemblyMT 13 Transmission Transmission Technical Performance Overview Structure pattern The 17G1A8 25 transmission is a mechanically manual transmission with 5 forward speeds and 1 rever
95. wdriver C gt lt gt a Removal Holder portion of clip must be spread out to remove rod fon Rotate 45 lt P to remove Pe Removal 7 BF 1 Cab Cab Front Panel Disassembly of the front bumper assy 1 Remove the fixed bolt of front bumper 2 Disassemble the connection device for right and left fog light 3 Remove the bumper assy 4 Disassemble the clip and bolt BF 2 Cab Door Front Door Note When disassembling the front door it is better to disassemble the cover at front side first eAfter adjusting the door or door lock check the door lock open and lock condit ion Door glass regulator Door glass sub channel assembly adjustment Rear lower sash Outside handle adjustment gay Striker adjustment t O 13 16 Door hinge BF 3 Cab Instrument Panel Note Before disassembling the instrument panel switch off the power supply ee careful not to scratch pad and other parts These parts are made of plactic Excessive force will damage them Cab arrangement o Tm D Sel CHB ete 1 Ignition lock 9 Fog light switch 2 Horn button 10 Heater switch 3 Combined light switch 11 Hazard warning light switch 4 Windshield wiper amp washer rod 12 Radio cassette 5 Compartment light switch 13 Cigarette lighter 6 Windshield switch 14 Ashtray 7 Vent 15 Storage box 8 Instrument panel 16 16 Glove box BF 4 Cab Cab Interior Trims and
96. y main checking procedures all the tools needed work skills latent procedures which are not listed in the larger diagram above To some more complicated assembly system in dictate them with diagrams one by one 6 The measuring units in this book are mainly international standard ones 7 The data and axplanation of maintenance are in the last pages of every chapter to be the reference 8 In the procedure marked Warning Notes Caution strictly observe these procedure norms to avoid body hurt and damage to some parts Warning indicates if you do not follow this instruction it will cause body hurts Note indicates if you do not follow this instruction it will cause some parts damaged Except some instructions of warning and notice again some help ful information are provided GL 3 General Maintenance Specifications It is necessary for periodical inspection and maintenance of a vehicle to extend its service life and improve on its power performance and fuel economy So periodical inspection and maintenance should be carefully and maintenance should be carefully and strictly implemented in accordance with the following specifications so as to achiveve maximal economic and social benefits The users have to do the maintenance according to this chapter The following schedule is only for mainte nance items with in 4 0000km it is also suitable for normal maintenance items after 40 000km AA Running in Maintenance Mile

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