DongFeng EQ1030T47D-820 Service Manual

EQ1030T47D-820

Light Commercial Truck

Service Manual

PEOPLE'S REPUBLIC OF CHINA

DONGFENG AUTOMOBIL CO.,LTD.

2006, 6

General

QD32 Engine

Clutch

Transmission

Front Suspension

TOC

Rear Axle & Rear Suspension

Propeller Shaft & Differential

Steering System

Brake System

Cab & Frame

Electric System

TOC

General

Preventive Measures

How to Use Manual ...................................................................................GL-3

Maintenance Specifications......................................................................GL-4

Grease Application Place and Schedule ................................................GL-7

Main Adjusting Data..................................................................................GL-8

Lubricant ......................................................................................................GL-8

Capacity Data ..............................................................................................GL-8

Fuel ................................................................................................................GL-9

Engine Lubricant ........................................................................................GL-9

Gear Oil ........................................................................................................GL-9

Transmission Gear Oil.............................................................................GL-10

Lubricating Grease ...................................................................................GL-10

Fluid for Brake and Clutch.....................................................................GL-10

Engine Coolant..........................................................................................GL-10

Tightening Torque ....................................................................................GL-10

..................................................................................GL-2

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

engine

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 & D Institute of DONGFENG AUTOMOBILE CO., LTD. is in charge of compiling.

COE, single row, with front independent suspension,

power steering, front disc and rear drum brake

2006,6

GL-1

General

Preventive Measures

See preventive measures below to get safe operation and suitable maintenance surely. These measures will not be repeated in the next pages.

1.Do not let engine run too long absolutely unless 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, refrigerant 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 careful 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 maintenance, and you have to see the SPARE PARTS CATALOG for parts booking.

5.The smaller diagram mainly indicate: every 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 helpful 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 maintenance items with in 4,0000km, it is also suitable for normal maintenance items after 40,000km.

△—Running-in Maintenance Mileage （1,500~2,500km）

☆—

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 I=Inspect

Replace if necessary.

A=adjust C=Clean D=Dry and check

Maintenance Items

Replace lubricant ★ Replace oil filter cartridge

★

Maintenance Items

Exhaust device and tighting of other nuts I Drive belt IIIII Engine coolant R R Cooling system I I I I Fuel pipeline I I Air filter CCCRCCCR Air inlet and outlet valve A A A A A Fuel spray nozzle Idle speed I I I I I

5 101520253035404550556065707580

RRRRRRRRRRRRRRRR

RRRRRRRR

Maintenance Intervals （× 1000km）

1 1020304050607080

请看注意（1）

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 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 environment 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 C D Oil and oil filter Replace Often

All types Replace Often

A E Fuel filter Replace Every 20,000km

Clutch

Maintenance Items

Check working condition of clutch

Check clutch pedal free play

Check hydraulic pipe line and pump for leakage

Transmission

Maintenance Items

Check transmission for oil leakage

Check transmission oil level

Check worn condition between transmission and propeller shaft spline

Check the connections of control mechanism for looseness

Replace transmission lubricant oil

Brake system

Maintenance Items

Check effectiveness of service brake and parking brake

Check brake line for oil leakage

Check remain hydraulic oil of clutch and brake system

Check the tightness of the brake support plate

Check brake pedal free play

Check brake shoe for wearing

Check vacuum booster oil pipe and valve for oil leakage

Check brake drum and brake disc for wearing

Replace hydraulic oil of clutch and brake system

Check parking brake lever and steel wire for the working condition

Maintenance Intervals( × 1,000km）

4 8 12 16 20 24 28 32 36 40

△

☆★★★★★★★★★★ ☆★★★★★★★★★★ ☆★★★★★★★★★★

Maintenance Intervals( × 1,000km）

4 8 12 16 20 24 28 32 36 40

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Maintenance Intervals( × 1,000km）

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Steering system

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

Maintenance Intervals( × 1,000km）

4 8 12 16 20 24 28 32 36 40

△ ☆★★★★★★★★★★ ☆★★★★★★★★★★ ☆★★★★★★★★★★

Steering system

General

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 operating

Check steering gear oil level,add if necessary

Check spline hub of the steering drive shaft for wear

Check and adjust front wheel toe-in

Check the tightening condition of upper and lower cross arm ball head to steering knuckle

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

Suspension system

Maintenance Items

Check shock absorber for oil leakage and fasten bracket bolts

Clean rear leaf spring and shock absorber

Check the working condition of the front independent suspension upper and lower cross arm ball pin and the dust cap

Check the working condition of torsion bar fixed adjusting arm

Tighten U-bolts and nuts of leaf spring during full load

Check the working condition of front suspension torsion bar and push rod

Check the working condition of front independent suspendion upper and lower cross arm

Tighten the connecting bolt of front independent suspension

Check the tightening condition of leaf spring shackle bolt

Check the working condition of rubber assist spring

Check leaf spring and shock absorber for any damage

Replace leaf spring pins and sleeves

Check the working condition of front independent suspendion rubber limit block

Check the vehicle left and right height

Maintenance Intervals( × 1,000km）

4 8 12 16 20 24 28 32 36 40

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Maintenance Intervals( × 1,000km）

4 8 12 16 20 24 28 32 36 40

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＊ 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 Items

Check shaft connecting part for looseness

Check tightening condition of spider bearing of propeller shaft

Check propeller shaft splines for wear and damage

GL-6

Maintenance Intervals( × 1,000km）

4 8 12 16 20 24 28 32 36 40

△

☆★★★★★★★★★★ ☆★★★★★ ☆★★★★★

Axle & wheel

General

Maintenance Items

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

Rotate tires

Replace the main reductor lubricant

Other

Maintenance Items

Check the connecting part tightening conditions of cargobody to frame

Check thelongitudinal and cross member of the cargo body for looseness and damage

Check chassis frame rivets for looseness

Check connections of cab for looseness

Check battery electrolyte level (fill up if it is not enough)

Maintenance Intervals( × 1,000km）

4 8 12 16 20 24 28 32 36 40

△

☆★★★★★★★★★★ ☆★★★★★★★★★★ ☆★★★★★★★★★★ ☆★★★★★★★★★★ ☆★★★★★

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Maintenance Intervals( × 1,000km）

4 8 12 16 20 24 28 32 36 40

△

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☆★★ ☆★★★★★ ☆★★★★★

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 Items

Rubber parts of brake valves

Rubber hoses of brake system

Rubber hoses for vacuum pump

Rubber hoses of clutch control system

Rubber sealing ring of master and slave cylinder of clutch

Front independent suspension upper and lower cross arm ball pin assembly

Propeller shaft spider assembly

Steering drive shaft spider ball pin assembly

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Replace Intervals (Year)

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, 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.

△—Running-in maintenance mileage (1,500~2,500km)

GL-7

General

☆—Running-in maintenance lubrication item

★—

Normal driving lubricating item

Place of lubricating

Slip yoke of steering drive shaft and spider bearing

Door hinge

Door lock, glass regulator, odometer flexible shaft

Hub bearing

Lubricating interval mileage （× 1,000km）

4 8 12 16 20 24 28 32 36 40

△

☆★★★★★ ☆★★ ☆★★ ☆★★

Main Adjusting Data

Adjusting Items Standard

Air valve clearance (cold)

Inlet valve

Exhaust valve Oil pressure of idling engine Oil pressure of normal run engine Water temperature of normal run engine

Tension grade of alternator belt 10~15mm

Free travel of clutch pedal Free play of brake pedal Steering wheel free play Toe-in

0.35mm

69~100kPa

196~490kPa

80~95 ℃

25~40mm

20~25mm

10°

0~2mm

Lubricant

Place Lubricant Type Grade

Engine lubricating system Engine cooling system Antifreeze, anti-rust coolan

Transmission Manual operation special oil

Main reductor Industrial gear oil

Steering gear

Clutch & brake system Synthetic brake liquid

Bearing and ball pin Li-base lubricant grease

Engine oil

Power steering fluid

5W/20 API CF-4

75W/90 API GL-4 75W/90 API GL-5

ATF-2

901-4 DOT4

2, 3#

Capacity Data

Part Capacity (L)

Fuel tank 65 Engine lubricant system 6.5

Water tank and cooling system 13 to full

Transmission 2.7 Main reductor Steering gear Brake system

6.5~5.0 to overflow

to the MAX

SH0535-93

GL-8

General

Fuel

The qualified light diesel oil specified by GB/T19147-2003 could be applied for in China, and the

users choose different qualified light diesel oil according to the local temperature.

0# Light diesel oil

10# Light diesel oil

20# Light diesel oil

35# Light diesel oil

50# Light diesel oil

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.

Local temperature above 4 ℃

Local temperature above -5 ℃

Local temperature between -5 ℃ ~ -14 ℃

Local temperature between -14 ℃ ~ -29 ℃

Local temperature between -29 ℃ ~ -44 ℃

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 temperature range is as below.

Gear Oil

Middle-load (API GL-4) gear oil, heavy-load (GL-5) gear oil is recommended. The recommended ambient temperature range for all gear oil is as below:

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 ℃ .

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) 108~127

Lower cross arm cotter pin fixed nut 118~191

Upper bracket nut of front shock absorber 32~42

Tighten nut of front shock absorber upper end 16~22

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 shackle 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 connecting part

Engine rear mounting bracket and cushion connecting part

Transmission bolt and rear mounting bracket connecting part

Follow EQB-37-1999

88~108

GL-10

General

Part Tightening torque (N.m)

Transition output shaft and propeller shaft connecting part

Transition control flexible shaft fixed bracket and longitudinal 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 connecting part

Engine front mounting cushion nut 46~56

Engine and clutch housing conneting part 39~49

Engine exhaust pipe and vehicle exhaust pipe connecting part

Steering wheel locking nut 29~39

Steering gear and steering gear drive shaft universal knuckle fork connecting nut

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 fixed 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 nut

Steering knuckle and lower cross arm ball head fixed 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 & rear mounting bracket and frame 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 connecting part

Fuel tank bracket and frame connecting part 21~28

Fuel tank band fixed bolt part 20~23

69~78

13~16

30~41

51~65

25~29

88~137

78~98

118~191

60~72

21~25

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 fixed 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

TOC

Clutch

Precaution and Preparation

Clutch System .............................................................................................CL-3

Clutch Control System .............................................................................. CL-4

Clutch Release Mechanism ......................................................................CL-6

Clutch Driven Disc and Pressure Plate .................................................. CL-7

Service Data and Specifications.............................................................. CL-9

...................................................................... CL-1

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 disc, use the dust collector to clean the dirt, not the compressed air.

Preparation

Specified tools

CL-1

Clutch System

Clutch

1.Clutch pedal bracket assy

2.Rubber hose assy--oil reservoir to master pump

3.Clutch master pump assy

4.Clutch pedal welding assy

5.Pedal jacket

6.Clutch pedal shaft

7.Clutch pedal return spring

8.Lower fixed board

9.Dustproof

10.Front oil pipe assy

Spacer

11.

12.Rear oil pipe assy

13.

Clutch rear bent pipe bracket

14.Hose assy

15.Gasket

16.Clutch slave pump assy

CL-2

Clutch

Adjusting Clutch Pedal

1.Adjust the pedal height by means the spacing screw.

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 circles, screw down the locking nut at last.

Pedal free play A：

30~50mm

Bleeding Procedure

Bleed air according 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 Control System

Clutch master pump

Clutch

1.Oil intake joint

2.Dual wire clamp

3.Pump body

4.Return spring

5.Piston oil intake valve return spring seat

6.Piston oil intake valve return spring

7.Piston oil intake valve oil seal

8.Piston oil intake valve

9.Oil pipe joint

10.Limit screw seal ring

CL-4

11.Limit screw

12.Rubber cup

13.Piston

14.Retainer ring

15.Push rod thread fork

16.Hex thin nut

17.Push rod spacer

18.Push rod

19.Dustproof

Clutch

Disassembly and assembly

Push pistion into cylinder body with screwdriver when removing or tightening valve stopper screw.

Align groove of piston assembly and valve stopper when installing valve stopper screw.

Clutch slave pump

1.Slave pump push rod nut

2.Shield

3.Push rod

4.Piston

5.Rubber cup

6.Pump body

7.Oil drain screw plug

8.Dustproof

Inspection

1.Check rubbing surface of slave cylinder for wear, rust or damage.

2.Check piston cup for wear or damage. Replace 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 Release Mechanism

Clutch

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 bearing 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.

Warn ing

•Too much grease might result in damage to the clutch driven disc

Clutch Driven Disc and Pressure Plate

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 disc; 　

Check whether the driven disc has been burnt, discolored or polluted with oil or grease. Change it if necessary.

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

·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.

·Check whether the pressure surface of the pressure plate is burnt or dirt-

ied. Remedy it with the emery paper.

CL-8

Clutch

·Check whether the matching surface of the pressure plate and driven disc

has deformation or damage. Change them if necessary.

·Adjust the unevenness of the diaphragm spring with tool.

Flywheel check

·Check whether the working surface of the flywheel is burnt or discolored.

Remedy it with the emery paper.

Check its surface for planeness.

Clutch cover 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.

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

Effective thickness of the friction lining 1.2mm(Nominal size)

0.3mm

Clutch pressure plate

Diaphragm spring height: 41-43mm

CL-9

Clutch

CL-10

TOC

Transmission

Technical Performance Overview

Service and Maintenance Notes for Transmission............................. MT-1

Trouble and Troubleshooting.................................................................. MT-1

Disassembling Procedures and Notes for Transmission Assembly MT-2

Check and Repair .................................................................................... MT-11

Reassembling Procedures and Notes for Transmission AssemblyMT-13

.......................................................... MT-1

Transmission

Technical Performance Overview

Structure pattern

The 17G1A8-25 transmission is a mechanically manual transmission with 5 forward speeds and 1 reverse speed. All the forward speeds are synchromeshed. 5th speed is overdrive gear. All of them apply skew cylindrical gear engagement and the gear shifting is smooth.

Gear ratio

1st speed 2nd speed 3rd speed 4th speed 5th speed Reverse speed

5.016 2.672 1.585 1.000 0.77 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 lightduty 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 &Trouble shooting

1. Check the operating system to see whether the shifter rock arm of transmission is pushed in position, or dismount the transmission cover and push the fork by hand to engage the gear, check the engagement condition.

2. If not completely engaged,check the fork for deformation or overwear of working suface.

3. If the gear sleeve is completely engaged, check the gear sleeve and the back taper part of connecting tooth for wear.

4. If the clearance is too large when stirring the 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.

Disengagement

1.The transmission shifts into neutral automatically during driving.

1.Wear of fork shaft circular groove and interlock pin, plastic deformation of lock ball spring.

2.Wear of fork working surface.

3.Wear of connecting cone for synchronizer toothed ring and gear sleeve.

4.Axial looseness of gear.

MT-1

Transmission

Trouble Phenomenon Probable case Judgement &Trouble shooting

The gear couldn't be engaged properly.

Noise

1.Without the failure of clutch,shifting is difficult with serious pound or disengagement at some gear is hard.

1.Regular pound

2.Even noise.

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.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.Check the faulty area and remove the failure.

1.Disassemble,inspect, clean or replace damaged 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

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