Jiefang

CA4250P25K15T1E5A80
Flat-headed diesel semi-trailer tractor
Maintenance manual
The whole vehicle and use instructions of the
manual

FAW Jiefang Qingdao Automobile Co., Ltd

December 2020
 Foreword
Welcome to choose jiefang truck products.
Jiefang CA4250P25K15T1E5A80 is equipped with Xichai CA6DM3-50E5 engine which meets the national
IV emission standard ; Φ 430mm clutch; ZF16S2531TO gearbox; 457 upgrade axle; The front spring is less leaf
spring and the rear air spring is membrane type; The front suspension adopts the lifting ring structure and is
equipped with Φ 36mm two-way acting cylinder hydraulic shock absorber; The rear suspension adopts the lifting
ring structure and is equipped with Φ 45mm two-way acting cylinder hydraulic shock absorber cylinder type
hydraulic shock absorber; Front and rear service brake are disc brake; A cab with JH6 flat floor, high roof and
large row half cab.
The maintenance manual is divided into 13 separate books according to the compilation of the assembly:
"complete vehicle"; "engine"; "engine accessories"; "electrical"; "clutch"; "gearbox"; "transmission and control";
"drive shaft"; "front axle and steering"; "drive axle"; "suspension"; "braking"; car body, etc.
In order to meet the needs of users and maintenance personnel for vehicle maintenance and service
technology, a set of maintenance manual is prepared. It mainly introduces the specification, structure, disassembly
and assembly sequence, overhaul standard, tightening torque, special tools, lubricant, overhaul method,
maintenance, fault analysis, etc. It is a comprehensive, practical and highly instructive book on professional
automobile maintenance.
This book is up to date in print and subject to revision.
December 2020
 Contents
How to read this manual ……………………………………………Volume 1
Vehicle……………………………………………………………………Volume 1
Engine……………………………………………………………………Volume 2
Engine accessories………………………………………………….…Volume 3
Electrical…………………………………………………………………Volume 4
Clutch……………………………………………………………………Volume 5
Transmission and control……………………………………………Volume 6
Transmission…………………………………………………………Volume 7
Transmission shaft……………………………………………………Volume 8
Front axle and steering ……………………………………………Volume 9
Suspension…………………………………………………………….…Volume 10
Drive axle…………………………………………………………………Volume 11
Braking …………………………………………………………………Volume 12
Vehicle body………………………………………………………………Volume 13
 How to read this manual

How to read this manual

Contents of this manual …………………………………………………2

Chapter structure of this manual………………………………………..3
Terms and units…………………………………………………..………8

1
 How to read this manual

Contents of this manual compilation

This manual is divided into several parts, and each system of the car is a chapter.
Each chapter mainly includes specifications; structure; maintenance standards; tightening torque；lubricant, oil
and sealant；special tools; troubleshooting methods and fault analysis.
The page numbers of each chapter are separately compiled, and the first page is always 1.

Numbe
Name Contents
r
The whole vehicle and
1 Product description, performance and main technical parameters
operation instructions
2 Engine Engine body
Oil supply system, air intake system, exhaust system, exhaust brake,
3 Engine accessories
cooling system, lubrication system.
4 Electrical Electrical equipment, electrical circuit diagram
5 Clutch Clutch body and clutch control
6 Transmission and control Transmission body and control
7 Transmission Transmission body
8 Transmission shaft Middle bridge drive shaft, rear bridge drive shaft
9 Front axle and steering Front axle, wheels, steering system
10 Suspension Front suspension, rear suspension
11 Drive axle Middle bridge, rear bridge
12 Braking system Brake, brake system
13 Body Cabs suspension, doors, body, air conditioner, interior and exterior

2
 How to read this manual
Chapter structure of this manual
Each chapter mainly contains the following parts (the front axle and steering as example) :

Other information related to

system components such as
specifications, parameters and
dimensions.

The structure of the whole system

and its components.

Preparation work required before and after

installation (such as process support, oil
discharge, and disassembling other parts
first).

Description of the maintenance

method for the maintenance
requirements (see the following
instructions for details).

Possible failures, causes and

maintenance methods of the whole
system.

Maintenance required in use of the

system

3
 How to read this manual
1. The structure and contents of each chapter

The name of the chapter

⑦Special tools

System or assembly name

Decomposition diagram
The labels are arranged
in order of decomposition.

②Disassembly sequence ⑧Inspection and

maintenance

③Assembly sequence

④Maintenance standard

⑤Tightening torque

⑥Lubricant (oil and/or

sealant)
The grades and quantities of oil,
grease and / or sealant used.

4
 How to read this manual
Ⅱ. Annotation

Detailed as follows
When carrying out maintenance, we should first look①at the decomposition diagram, and then look at the②～
⑧ other parts from.

②Maintenance standard

Part Maintenance projects Standard value: Limit value Correction methods

Starting torque of wheel Tangential force at hub bolts

13、16、17、25 2.80～7.67 N.m —
hub bearings is 16.7～45.0N

③Tightening torque

Part Tightening parts Tightening torque Remarks

6 Hub cover mounting bolt 16～30 -

9 Adjusting nut for hub lock nut 6.87～8.81 -

④Lubricant (oil and/or sealant)

Part Coating position Prescribed lubricant Number

7 Wheel hub cover Wheel bearing grease 120g

21 Inside the wheel hub Wheel bearing grease 500g

5
 How to read this manual
⑤Special tools
Part Title Graphic Use

Removal and installation

11 Socket wrench
of lock nut

⑥Maintenance and repair methods

Insert the shoulder of the hub bolt [20] into the groove on the hub
[21] and install the brake drum 19.
Attention
When installing hub bolt [20], the end with a large radius of rounded
corners at the root should face the outside of the vehicle.
Screw the hub and the brake drum together with the inner nut of the
brake drum [18].
The nut [18] should be tightened to the specified torque：490～
580N.m
Tap the threaded end of bolt 20 toward the end of the nut for two
small turns.

6
 How to read this manual
3. Description of the serial number and symbol mark in the decomposition diagram:
1）The part numbers in the figure are sorted by the disassembling sequence of the assembly or system.
2）There are two ways to express assembling sequence:
(1) If the order of assembly is opposite to that of disassembly, it’s written as "in reverse order of disassembly ".
(2) If assembly is not carried out in the reverse order of disassembly, but some small assemblies are first
assembled and then assembled with other parts, the form of serial number and arrow is used.
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┘
The tabs that may be used are: "┐ ┘ ├ ┴ ┤ │ ─ →"
3）A special illustration on the figure shows the meaning of the symbol tag in the following table

Graphi
Instructions Remarks
c
Indicates that lubricant, oil and sealant need to be added.
Represents a part that cannot be reused.
A part may have
Represents the requirement of tightening torque.
more than one mark.
The figure enclosed in square brackets indicates that the part will be
[14]
explained in the maintenance method.
The piece with a * indicates that it is explained in other chapters, where the
*
assembly relation is expressed only.
A graphic representation referring to the contents of other chapters or page This mark appears in
vumbers. the annotation
See the following
Represents the use of specialized tools. instructions for
details
4. Related requirements and instructions for special tools
Each special tool is marked with a symbol . The troubleshooting method also includes the name of the
special tool. If you want to know the part number and shape of the special tool, you can look it up in the "special

tools" table. If more than one special tool is used, letters (e.g 、 、 ) can be attached for cross reference
between exploded view and maintenance method.

For example：

7
 How to read this manual

Check or adjust valve clearance

：16mm Special socket wrench

：Feeler gauge

Terms and units

This manual provides important warning instructions and supplementary information under the following
four headings. These four headings respectively indicate the characteristics of these instructions and information:

Headline Instructions
Recommendations or supplementary information for more efficient use of equipment or better
Remarks
understanding of the content.
Preventive instructions, if not followed, may result in damage or destruction to equipment or
Attention
parts.
Warning Preventive instructions, if not followed, may result in serious injury or death.
Maintenance standard terms
(1) Standard value:
Standard value in design refers to the design size of each part, the standard gap between two parts during
assembly, and the standard value of an assembly part, which depends on the situation.
(2) Limit value
When the value of a part exceeds this limit, the part is no longer usable in terms of performance and strength
and must be replaced or repaired.
Tightening torque
Proper tightening torque is of particular importance to performance. Therefore, the tightening torque is
specified at the location of the tightening.
If there is no specified tightening torque value, please operate following the table for standard tightening
torque.
Wet word should be indicated where tightening is done in wet state. If not specified, shall be deemed as dry
state and shall be tightened according to the prescribed torque.

8
 How to read this manual

Standard torque meters commonly used

Material 35，45 15MnVB, 45 40Cr, 40MnB

Hardness HB167-207 HB283～321 HRC35^0
Mechanical performance
5.6 Level 8.8 Level 10.9 Level
grades
Tightening torque
N.m(σs=300N/mm2) N.m(σ0.2=640N/mm2) N.m(σ0.2=800N/mm2)
Specific
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
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

9
 Overview of the vehicle

Vehicle

MAIN TECHNICAL PARAMETERS OF THE WHOLE

VEHICLE………………………2

BRIEF SPECIFICATION OF MAIN

ASSEMBLY…………………………………. 3

1
 Overview of the vehicle

Main technical parameters of the vehicle

Weight parameter

Mass (kg) 8805

Full-loaded mass(kg) 25000
Front axle (kg) 4600
No-load
Distribution Rear axle (kg) 4205
of axle load Front axle (kg) 7000
Full load
Rear axle (kg) 18000
Number of cabin crew(people) 2
Dimension parameters

Length(mm) 6990
Overall dimensions Width (mm) 2500
High (mm) 3995
The wheelbase (mm) 3400+1350
The front wheel
2042
(mm)
Tread
The rear wheels
1852
(mm)
Front suspension(mm) 1495
Rear suspension(mm) 745
Minimum ground clearance (full load)(mm) 222
Minimum turning diameter (as per center of outer wheel
≤15
track)(m)
Approach angle(°) 17
Vehicle passing angle (full load)
Departure angle(°) 40
Performance parameters

Maximum speed (full load, flat and good road)(km/h) 110

Maximum gradient (driving at constant speed with full load, 40%

on dry and hard road)

Parking gradient (full load, up and down directions) 15%

Max range (km) 2000

2
 Overview of the vehicle
Outside noise in accelerating 84

Average fuel consumption under limited conditions (60km/h) 38

3
 Overview of the vehicle
Capacity parameter

The oil Filling volume

Clutch hydraulic control mechanism hydraulic oil（L） About 0.35 L
Power steering gear and its oil tanks（L） About 5 L
Hydraulic oil of cab hydraulic turnover mechanism（L） About 0.6 L
Windscreen wash liquid（L） About 1.5 L
Coolant（L） About 41 L
Middle axle 17L+2L (wheel end)
Drive axle（L）
Rear axle 17L+2L (wheel end)
Brief technical specification of main assemblies
Engine
Xichai CA6DM3-50E5 six cylinder, four stroke, water-cooled, direct injection, supercharged and intercooled
engine. Rated power/speed 370kW(1800r/min), maximum torque/speed 2300N·m(1300r/min)，displacement
12.5L，compression ratio 17：1.
Clutch
Single, dry, diaphragm spring compression type. Friction disc diameter is Φ430mm。The operating mechanism of
the clutch is hydraulic air booster type.
Transmission
ZF16S2531 TO transmission with double H and super H shift operation mode.
Rear axle
457 upgrade axle, single-grade reduction；main reduction ratio i=4.1.
Frame
Edge-beam punch-riveted structure, maximum section size of longitudinal beam：300×80×8mm.
Suspension
The front spring is a few leaf spring, and the rear air spring is a membrane type; The front suspension adopts the
ring structure and is equipped with a Φ 36mm double acting cylinder hydraulic shock absorber; The rear
suspension adopts the ring structure and is equipped with a Φ 45mm double acting cylinder hydraulic damper.
Front axle
Adopt 2020 front axle, integral forging and pressing," 工 "shape section, reverse elliott axle.
Wheels and spare wheel lifters

Tires 315/80R22.5-20PR
Rim 22.5X9.00
Tire pressure 830kpa

4
 Overview of the vehicle
Braking system

Title Type

Front wheel brake Disc brake

Rear wheel brake Disc brake

Hand brake valve Piston type

Brake valve Double - chamber piston in series

Diaphragm-type four-circuit protection valve, integral air dryer,
Air treatment unit assembly
unloading valve, safety valve

Hand relay valve Piston pressure balance type

Relay valve Piston pressure balance type

Brake chamber Diaphragm type

Trailer coupling Hand-operated quick-change connectors meeting GB13881

requirements
Trailer brake valve Piston pressure balance type

Check valve Rubber valve

Diaphragm type brake air chamber for front chamber, piston type
Spring brake cylinder
spring brake cylinder for rear chamber
Cab

A cab with JH6 flat floor, high roof and large row half cab, all floating cab suspension, front and rear suspension
are air spring suspension, and manual and electric integrated hydraulic turnover.