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Jiefang

CA4180P66K24E4Z
Cab Over Engine Diesel Tractor-Truck
Service Manual

China FAW Co., Ltd.


Foreword

Welcome to choose upgraded Jiefang J6 truck products.

Jiefang CA4180P66K24E4Z 4×2 series are equipped with CA6DM2-42E4 diesel


engine SACHSΦ430 clutch , ZF16S2210D transmission , 2020 front axle,
R13D498 axle, drum type brake, 12R22.5 tires and J6 upgraded cab. The front
suspensions of these series are leaf spring of semi-ellipse type and longitudinal
symmetry. The rear end of front suspension is ring type and equipped with
double-action telescopic shock absorber. The rear suspensions are of main and
auxiliary leaf springs.
This service manual is compiled by assembly and divided into 13 offprints:
Vehicle, Engine, Engine Accessories, Electric Controls, Electrical, Clutch,
Transmission & Control, Propeller Shafts, Leading Axle & Steering, Drive Axles,
Suspensions, Brake System, and Body.
A set of service manual offprints is hereby compiled to meet customers and
maintenance personnel’s need for vehicle maintenance and repair techniques.
The manual highlights specifications, construction, removal and installation
sequences, inspection standards, tightening torques, special tools, lubricants,
inspection methods, repair and maintenance, fault analysis, etc. It is a
comprehensive and strongly instructive professional vehicle maintenance
literature with high utility.
This book contains the latest information at the time it is printed. The
modifications will be included in the revision when it is reprinted.

Jan. 2013
Content

How to Read This Manual ···························································· 1


Vehicle ···················································································· 1
Engine ···················································································· 2
Engine Accessories ····································································· 3
Electric Controls········································································ 4
Electrical ················································································· 5
Clutch ····················································································· 6
Transmission & Control ······························································ 7
Propeller Shafts ········································································· 8
Leading Axle & Steering ······························································ 9
Drive Axles ·············································································· 10
Suspensions ············································································· 11
Brake System ··········································································· 12
Body ······················································································ 13
How to Read This Manual

Compilation Content of this Manual ··············································· 2


Section structure of this Manual ···················································· 3
Terminology & Units ·································································· 7

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How to Read This Manual
Compilation Content of this Manual
 This manual is divided into numbers of sections, each of which describes a separate system of the vehicle.

 Each section mainly covers specifications, construction, maintenance standard, tightening torques,
lubricants, oils and sealants, special tools, inspection methods and fault analysis.
 Pages of sections are numbered separately. The numbering always starts from 1.

Section number Section name Content


Product overview, specifications and main technical data, use and
1 Vehicle
maintenance of jack
2 Engine Engine body
Fuel supply system, intake system, exhaust system, exhaust
3 Engine Accessories
brake, cooling system, lubrication system
4 Electric Controls Engine electronic control system, ABS
5 Electrical Vehicle electrical equipment, electric circuit diagrams
6 Clutch Clutch body and control
7 Transmission & Control Transmission body and control
8 Propeller Shafts Middle axle propeller shaft, rear axle propeller shaft
9 Leading Axle & Steering Leading axle, wheels, steering system
10 Drive Axles Middle axle, rear axle
11 Suspensions Front suspension, rear suspension
12 Brake System Brakes, brake system
Cab mounting, doors, bodywork, air conditioner, interior and
13 Body
exterior trims

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How to Read This Manual
Section structure of this Manual
Each section mainly includes the following parts (take “Leading Axle & Steering” as an example):

Specifications, parameters, I. Specification .......................................................................... 2


dimensions, etc. and other
data related to system parts II. Structure ................................................................................ 3
III. Operation before assemble and after installation .................. 3
Adjustment of wheel alignment ............................................ 4
Description of construction
of entire system and its parts IV. Wheel hub and brake drum ................................................... 6
Disassembly sequence ........................................................... 6
Testing standard ...................................................................... 7
Preparations required before Tightening torque .................................................................... 7
removal and installation and
after installation (e.g. process Lubricant ............................................................................... 7
supports, oil draining, and
removal of other parts Special tools ............................................................................ 7
beforehand) Testing method ...................................................................... 8
V. Knuckle and kingpin of front axle ......................................... 9
Testing standard .................................................................... 10
Tightening torque .................................................................. 11
Special tools .......................................................................... 11
Testing method ...................................................................... 11
VI. Wheel .................................................................................... 14
Disassembly sequence ......................................................... 14
Tightening torque .................................................................. 14
Description of notes of
inspection method for items Lubricant ............................................................................. 15
having maintenance
requirements (see the Special tools .......................................................................... 15
instructions below for details)
Testing method ...................................................................... 15
VII. Steering and control mechanism ......................................... 17
Disassembly sequence ......................................................... 17
Assembly sequence ............................................................. 17
Tightening torque .................................................................. 17
Special tools .......................................................................... 18
Testing method ...................................................................... 18
VIII. Steering pipeline ................................................................. 19
Disassembly sequence ......................................................... 19
Symptoms, causes and
remedies of problems that Assembly sequence ............................................................. 19
may exist in entire system Tightening torque .................................................................. 20
Special tools .......................................................................... 20
Testing method ...................................................................... 20
Service and maintenance items
VIIII. Typical failure analysis ....................................................... 22
required during use of system
X. Operation and maintenance ................................................. 22
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How to Read This Manual
I. Structure and Content of Each Section

Section name Section number

⑤ Special
tool

Name of system or
assembly

① Exploded
view
Mark numbers
are arranged in
disassembly
sequence.
⑥ Inspection
method
② Inspection
standard

③ Tightening
torques

④ Lubricant, oil and/or sealant


Grade and amount of machine oil,
grease and/or sealant used

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How to Read This Manual
II. Detailed Description of Notes ①~⑥ (Below)
During maintenance, you must examine the exploded view ① first, and then see
other parts (②~⑥).


④ Lubricant (oil and/or sealant)

Area Location of application Specified grease Amount


7 Wheel hub cap Wheel bearing grease 120g
21 Interior of wheel hub Wheel bearing grease 500g

⑤ Special tool

Area Name and shape of tool Purpose


Socket wrench

Removing and
11 installing lock
nuts

⑥ Inspection method
 Place the shoulder of the hub stud bolt [20]
in the groove on the hub [21], and install
the brake drum [19].
② Inspection standard 19 Caution
The hub stud bolt [20] should be installed with
Standard Limit its end having a larger root fillet radius facing
Area Maintenance item Method of correction outside of the vehicle.
value value
13, 16 Starting torque of 2.80~7.67 Tangential force at hub  The hub and brake drum are tightened
— together by the inner nut [18] securing the
17, 25 wheel hub bearing N.m bolt: 16.7~45.0N
[18] [20] brake drum.
③ Tightening torques The nut [18] must be tightened to the
specified torque (490~580 N.m).
Area Part to be tightened Tightening torque Remark  Tap out 2 small flangings on the end face of
6 Mounting bolt of hub cap 16~30 - the head of the bolt [20] facing the nut to
9 Adjusting nut of hub lock nut 6.87~8.81 - prevent looseness.

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How to Read This Manual
III. Description of SNs, Symbols and Marks in the Exploded View
1) Numbers of the parts in the drawing are sequenced in the order of disassembly of the assembly or system.
2) An assembly sequence is expressed in 2 ways:
(1) If assembly is in the reverse order of disassembly, it will be written as “in the reverse order of disassembly”.
(2) If some small assemblies are fitted together first and then they are combined with other parts (i.e. assembly is
not in the reverse order of disassembly), it will be expressed in the form of “SN + arrow mark”. For example:
25→24┐

26┴→23→22┐
├→19→12→11→18→17→16→15→14→13→10→9→8→7→6→5→4
27→21→20┘
Tabulation characters that may be used include: “┐ ┘ ├ ┴ ┤ │ ─ →”.
(3) Special notes as well as meanings of symbols and marks on the drawing are set forth in the table below.

Graphics Interpretation Remark


Lubricant, oil and sealant need to be added to this place.
A non-reusable part
Multiple marks for
Tightening torque requirement is available. one part are allowed.
A figure enclosed by a pair of brackets. It means that the part will be
[14]
described in inspection method.
A part with “*” means that the part is described in other section and that it is
*
listed here to express an assembly relationship only.
This mark appears in
A presentation graphic for reference to other section or page
notes on drawings.
See the instructions
It indicates that a special tool should be used.
below for details.

IV. Requirements and Descriptions Related to Special Tools


Each special tool is marked with a symbol. Names of special tools are also included in inspection methods. If
you want to make certain of part number and shape of a special tool, you can find corresponding information in
the “List of Special Tools”. If more than one special tool will be used, letters (e.g. , and ) can be added to
establish cross references between exploded views and inspection methods.
Example:
[25] When inspecting or adjusting valve clearance
: 16mm special socket wrench

a : Feeler gauge

[3]

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How to Read This Manual
V. Terminology & Units
This manual gives important warning instructions and additional information under the following 4 captions. The
4 captions suggest the features of these instructions and information respectively:

Caption Description
Advices given or supplementary information provided for making use of the equipment in a more
Remark
effective way or better understanding of related content
Preventive instructions. Failure to observe these instructions may cause damage to the equipment
Caution
or its parts or breakdown accident.
Preventive instructions. Failure to observe these instructions may cause serious injury or fatal
Warning
accident.

1. Terms used in inspection standards


(1) Standard value
A standard value in design refers to, as the case may be, a design dimension of a part, a standard clearance
between 2 parts during assembly, or a normalized value of an assembly part.
The numerical value enclosed in “{}” is a base diameter.
(2) Limit value
When this value of a part is exceeded, the part can no longer be used because of its poor performance and strength
and it must be replaced or repaired.
2. Tightening torque
Right tightening torque is of great significance to performance. Therefore, tightening torques are specified for
parts to be tightened.
Where no specific values of tightening torques are specified, please operate according to the Standard Tightening
Torque Table.
Attach a “Wet” label to each place where needs to be tightened when wet. Places not indicated should all be
deemed to be tightened when dry and must be tightened to specified torques.
Typical Standard Torque Table
Material 35, 45 15MnVB, 45 40Cr, 40MnB
Hardness HB167-207 HB283~321 HRC35^0
Mechanical performance rating Grade 5.6 Grade 8.8 Grade 10.9
Tightening torque
N.m(σs=300N/mm2) N.m(σ0.2=640N/mm2) N.m(σ0.2=800N/mm2)
Specification
M6 4~6.5 6~12
M8 8~15 16~30
M8×1 9~16 18~34
M10 18~30 36~63 50~80
Ml0×1 20~35 40~70 60~85
M12 30~47 70~110 90~135
M12×1.5 35~54 75~115 95~145
M12×l.25 37~56 80~120 100~150
M14 55~82 120~160 145~210
M14×1.5 56~84 130~180 160~230
M16 85~127 180~240 220~300
M16X1.5 90~136 190~260 240~320
M18 118~170 250~300 310~400

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How to Read This Manual
M18×1.5 130~190 280~320 350~430
M20 167~250 350~410 440-320
M20×l.5 185~270 390~450 490-580
M22×l.5 250~370 510~580 660~750
M24×1.5 330~490 620~700 870~960

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Vehicle Overview 1

Vehicle
Main technical data
Weights
Kerb weight 7900kg
Axle load distribution Unladen Leading axle 5240kg
Trailing axle 2660kg
Gross weight 18000kg
Axle load distribution Laden Leading axle 6600kg
Trailing axle 11400kg
Seating capacity in cab 3,2 persons
Permissible gross combination weight 35170kg
Combined gross weight 43000kg
Dimensions
Overall dimensions Length 6235mm
Width 2495mm
Height 3600mm
Wheel base 3600mm
Gauge Front wheel 2020mm
Rear wheel 1830mm
Front overhang 1500mm
Rear overhang 1135mm
Minimum ground clearance (laden) 220mm
Minimum turning diameter (by center of track of front outside wheel) 13.2m
Vehicle ramp angle (laden) Approach angle 18°
Departure angle 40°
Distance from back of cab to center of front wheel 800 mm
Fifth wheel lead (distance from longitudinal oscillation center to center of 650 mm
rear axle)
Maximum permissible front turning radius of tractor-truck 1700mm
Minimum permissible rear turning radius of tractor-truck 1850 mm
Specifications
Maximum speed (laden, on flat and favorable road surface) 90km/h
Gradeability (laden, without trailer, traveling at a constant speed on a dry, 33%
hard and firm road surface)
Parking gradient (laden, in both uphill and downhill directions) ≥12%
Maximum driving range 1500km
Outside noise during acceleration ≤ 80dB (A)
Average fuel consumption under limited conditions (80km) 33L/100km

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1 Vehicle Overview
Capacities
Fuel tank 600L
Cooling system 48L
Lubrication system (oil pan) 33L
Hydraulic control unit of clutch 0.3L
Transmission 14L
Drive axles Approx. 23L (rear axle)
Power steering gear and its steering fluid reservoir 4L
Hydraulic titling mechanism of cab Approx. 0.6L
Windshield washer fluid 3L

Brief technical specifications of principal assemblies


Engine
In-line six-cylinder, four-stroke, water-cooled, electronically controlled common rail, direct injection,
turbocharged and intercooled CA6DM2-42E4 engine with a maximum power of 309kW (1,900r/min), a
maximum torque of 1,900 N·m (1,300r/min), a displacement of 11L, a compression ratio of 18.2:1, and a 600L
fuel tank
Clutch
Diaphragm spring applied dry single plate clutch with a clutch plate diameter of Φ430mm
Transmission
ZF16S221OD transmission with mechanical joystick remote control and hydraulically operated clutch control
mechanism with air assistance
Propeller shafts
One open type propeller shafts with 2 universal joints; one middle axle propeller shaft with an axle tube size
(diameter x wall thickness) of Φ133mm × 5mm
Rear axle
CAR13D498 axle with single-stage reduction gear;final ratio i0=4.111。
Frame
Ladder type stamped and riveted structure with a maximum side rail section size of 300×800×8 mm
Suspensions
Front suspensions are of leaf spring type, longitudinal symmetry and semi-ellipse type. The rear end of front
suspension is of ring type and equipped with double-action telescopic shock absorber. The rear suspension is of
main and auxiliary leaf spring type.
Leading axle
Integrally forged and stamped 2020 leading axle with an I-section
Wheel and spare tire riser
Tire type 12R22.5
Rim 22.5x9.00
Tire pressure 840kPa

Steering system
Recirculating ball type integral power steering gear with a maximum working pressure of 15Mpa, a maximum
output torque of 6,650 N.m, and a transmission ratio of 23.3

Brake system

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Vehicle Overview 1

The brake system has two sets of independent control systems, namely double-loop service brake system actuating
on the front and rear wheels and parking & emergency brake system actuating on the rear wheels.
Service brake system has ABS and ASR,with its brake valve as pedal, series connection, double-chamber and
piston type. relay valve and manual relay valve are also installed. The chassis has a trailer brake valve used for
controlling trailer brake and joint used for supplying air for trailer and control, with manual control valve of trailer
being optional. Both front and rear service brakes are pneumatic drum type. Inside diameter of brake drum:
Ф400mm (front wheel), Ф410mm (rear wheel); width of shoe: 150mm (front wheel), 220mm (rear wheel). The
pneumatic control system of rear wheel brake system is fitted with a relay valve.
Parking brake (also as emergency brake): Fitted with a relay valve and controlled by spring brake cylinder and
manual valve, the system acts on rear axle.
There are total 3 air reservoirs: Two 35L reservoirs supply air for front wheel (35L) and rear wheel (35L) brakes
respectively. The remaining air reservoir is dual-chamber (15L+10L) type (the 15L chamber supplies air for
parking brake and trailer brake; the 10L chamber supplies air for such equipment as exhaust brake control,
pneumatic clutch booster, auxiliary transmission control and air horn).
The system is also provided with engine exhaust brake valve and control cylinder as well as electromagnetic
pneumatic control.
Electrical system and electric controls
24V vehicle electrical system (minus earth)
Two 6-QAW-180 batteries connected in series
Integral alternator (minus earth, 1.5kW, 28V, 75A)
Solenoid operated starter (voltage: 24V; maximum output power: 6kW)
Combination headlight consisting of headlight, front turn signal light, and front position light; combination
taillight comprising brake light, turn signal light, rear position light and reflector, backup light, license light,
Hazard warning lamp, rear outline marker light, and rear fog light.
Cab
The closed forward control cab of a brand new design features panoramic surface glass windshield, full-floating
mounting structure, and hydraulic tilt. Instrument panel and interior trims have brand new styles; multi-function
adjustable high-back driver’s seat and backrest angle adjustable passenger seat are provided (both seats are
equipped with seat belts). The cab is equipped with 3-speed electric wiper, single-arm window regulator, snap-in
door locks, auxiliary fascia console, windshield washer, plastic carpet, air conditioner, large spherical rear - view
mirror, air mixing heating system and multi-point spray defroster, and Freon-free refrigeration system.

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