3-CA4250P25K2T1E5A80-DY640-engine Accessories

Engine accessories maintenance manual
Jiefang
CA4250P25K2T1E5A80
Flat diesel semi trailer
Maintenance manual
Engine accessories
FAW Jiefang Qingdao Automobile Co., Ltd

November 2020
Contents
1. Oil supply system.............................................................................................................................................................1
1.1 Specifications..................................................................................................................................................................1
1.2 Operation before and after disassembly.........................................................................................................................1
1.3 Oil tank, bracket, hoop...................................................................................................................................................1
1.3.1 Tightening torque.........................................................................................................................................................2
1.4 Accelerator pedal............................................................................................................................................................2
1.5 Primary fuel filter...........................................................................................................................................................3
1.5.1 Tightening torque.........................................................................................................................................................3
1.5.2 Lubricant......................................................................................................................................................................4
1.5.3 Special tools.................................................................................................................................................................4
1.6 Common failures............................................................................................................................................................4
1.7 Use and maintenance......................................................................................................................................................4
2.Air intake system...............................................................................................................................................................4
2.1 Specifications..................................................................................................................................................................5
2.2 Work before disassembly and after installation..............................................................................................................5
2.2.1 Structure.......................................................................................................................................................................5
2.2.2 Maintenance method....................................................................................................................................................7
2.3 Common faults...............................................................................................................................................................8
2.4 Use and maintenance......................................................................................................................................................8
3.Exhaust system..................................................................................................................................................................8
3.1 Specifications..................................................................................................................................................................8
3.2 Work before disassembly and after installation..............................................................................................................9
3.2.1 Maintenance methods..................................................................................................................................................9
4. Cooling system...............................................................................................................................................................11
4.1 Specifications................................................................................................................................................................11
4.2 Work before disassembly and after installation............................................................................................................12
4.3 Structure........................................................................................................................................................................12
4.4 Intercooler.....................................................................................................................................................................15
4.4.1 Maintenance method..................................................................................................................................................15
4.5 Radiator and fan hood...................................................................................................................................................16
4.6 Fan and fan clutch.........................................................................................................................................................17
4.7 Common failures..........................................................................................................................................................18
4.8 Use and maintenance....................................................................................................................................................18
5 Urea box..........................................................................................................................................................................18
5.1. Specifications...............................................................................................................................................................18
5.2 Operation before and after disassembly.......................................................................................................................18
5.3 Assembly drawing of urea tank....................................................................................................................................19
5.4 Diagnosis and exclusion...............................................................................................................................................22
5.5 Use and maintenance....................................................................................................................................................22
1. Oil supply system
1.1 Specifications
Model 1101010-DY648
Fuel tank
Type 600L aluminum alloy square tank
Rated flow rate (L/h) 480

Fuel oil coarse filter
Diameter of inlet and
assembly M18×1.5
outlet threads (mm)
1.2 Operation before and after disassembly
Operation before disassembly
Engine flameout
When removing the fuel line, empty the fuel line
When removing the accelerator pedal, first pull out the electrical connector
Operation after installation
After installing the fuel line, drain the air in the line
1.3 Oil tank, bracket, hoop
S/N Part Name Serial Part Name
1
number
1 Nut - strap 8 Middle bracket assembly - fuel tank
2 Fastening belt assembly -fuel tank 9 Oil pipe locating mark
Feed pipe assembly - fuel oil strainer to

3 10 Sleeve1
engine
Return pipe assembly - engine to fuel

4 11 Rear bracket assembly - fuel tank
tank
5 Bolt1 12 Fuel tank assembly
6 Bolt2 13 Intake pipes and exhaust pipes
7 Front Bracket Assy-Fuel Tank 14 Fuel tank cover assembly
1.3.1 Tightening torque
Unit: N·m
Part Screwed parts Tightening torque
1 Hoop belt nut 60～70
5、6 Bracket bolts 150～250
1.4 Accelerator pedal
2
Serial
Serial
numbe Part Name Part Name
number
r
1 Hexagonal nut 3 Electronic accelerator pedal assembly
2 Assembling bolt
1.5 Primary fuel filter
Serial Serial
numbe Part Name numbe Part Name
r r
1 Oil filter sub-assembly 5 Fast connector
2 Upper cover assembly 6 Water level alarm assembly
3 Fuel filter main housing assembly 7 Oil filter core assembly
4 Water cup assembly
1.5.1 Tightening torque
Units: N·m
Part Screwed parts Tightening torque
3
6 Drain bolt assembly About 1.5
1.5.2 Lubricant
Part Coating position Prescribed lubricant Number
The surface is
6 Drain bolt assembly silicon seal Engine oil
uniformly coated
The surface is
2 Filter element silicon seal Engine oil
uniformly coated
1.5.3 Special tools
Part Tool Title Shape Use
Removal and
installation of fuel
Special wrench for Fuel oil
2 filter assembly
coarse filter
Disassembly and
installation
1.6 Common failures
Fault phenomenon Reason analysis Elimination method
Replace the gasket with a new

Gasket failure
one
Pipeline air leakage, oil
Pipeline rupture Replace pipeline
leakage
Tighten the joint as required
Loose connection
for torque
Fuel oil coarse filter cannot Oil impurities into the valve body or Replace the fuel oil coarse
pump oil normally diaphragm wear and tear and other reasons filter assembly
Replace with a new component

Oil leakage from fuel oil The sealing ring is lost or damaged during
or fuel oil coarse filter
coarse filter assembly maintenance, or the drain cup is damaged
assembly
1.7 Use and maintenance
Clean the fuel tank every 50,000 km.
Replace the filter element of the fuel coarse filter every 15000km; According to the situation of oil,
shorten the replacement mileage appropriately.
4
2.Air intake system
2.1 Specifications
Intake system form Cyclone drum-type knapsack inlet + double stage air filter
Type Paper dry air filter
Rated flow
25
Air cleaner rate（m3/min）
Inlet diameter(mm) 212×160
Outlet diameter(mm) 160
2.2 Work before disassembly and after installation
Work before disassembly
Tilt the cab forward
The cab falls back
2.2.1Structure
5
Serial Serial
numbe Part Name numbe Part Name
r r
1 Assembling bolt 24 Hexagonal nut
2 Air cleaner assembly 25 Large washer
3 Secondary filter element assembly 26 Shock absorber bracket assembly
4 Main filter element assembly 27 Rubber gasket
Connect base assembly - air

5 The air filter plugs the alarm assembly 28
filter(pattern)
Hexagon flange bolt thick rod (standard

6 29 Hexagonal nut
type)
Cross Recessed Pan Head Tapping Screw

7 Air filter holder assembly 30
and Plain Washer Subassembly
8 Air inlet pipe(pattern) 31 Assembling bolt
9 Heat shield B(pattern) 32 Connecting hose assembly-air filter
Worm-driven hose clamp assembly

10 Strap 33
(pattern)
11 Hexagonal nut 34 Inlet trim panel assembly(pattern)
6
12 Connecting rubber pipe(pattern) 35 Connecting rubber pipe
13 Heat shield A(pattern) 36 Spring washer
14 Reinforced hose clamp(pattern) 37 Spring washer
15 Shock absorber bracket assembly 38 Spring washer
16 Reinforced hose clamp(pattern) 39 Large washer
17 Reinforced hose clamp(pattern) 40 Assembling bolt
Worm-driven hose clamp assembly

18 Assembling bolt 41
(pattern)
19 Assembling bolt 42 Assembling bolt
20 Connecting rubber pipe 43 Shock absorber bracket assembly
21 Inlet assembly (the style drawing) 44 Inlet lower right bracket
22 Air inlet upper bracket assembly 45 Air filter base bracket Assembly
23 Hex socket head bolt 46 Worm drive hose clamp b type
2.2.2 Maintenance method
Loosen the circlip of the ash basin of the air cleaner [1], take down
the ash basin, pour out the dust scattered in the ash basin, and wipe
the ash basin with a rag.
Slowly remove the filter element and wipe away the dust scattered
[1]
inside the air filter case with a clean cloth.
Use clean compressed air of(400～600)kPa to blow out from inside

of the filter element and clean the filter element.
7
Before reassembly, check whether the sealing gasket at the front of
the filter element is intact and whether the filter paper is damaged. if
there is any damage, please replace the filter element with a new
one.
Load the filter element into the shell gently according to the correct
position, and press the filter element into the shell installation
position along the axis with both hands.
Slowly install the dust basin along the axis, adjust the position of the
dust bag to the original position, and then buckle the clamping
spring.
2.3 Common faults
Fault phenomenon Failure cause Elimination method
The seal strip of the rear end cover of the air

Filter element soaking Replace the new seal
filter is worn out or lost
Filter element broken Improper maintenance or scraping Replace the filter core
Damaged pipe line, loose seal Bump against something heavy, etc Replace with new parts
The air filter element must be maintained or replaced in time, otherwise the power of the engine will drop, fuel
consumption will increase and engine wear will be accelerated due to the blockage of the filter element. The filter
element shall be maintained every 10000Km and a new filter element shall be replaced every 30000Km.
See the maintenance method for detailed steps.
3.Exhaust system
3.1 Specifications
De NOx System(Selective Catalytic Reduction (SCR)

Post-processor assembly type
System)
Appearance and dimension of post processor (mm) Square, 557 (long)×390 (wide)×550 (high)
Postprocessor volume (L) About 100
Exhaust pipe line size (mm)(outside diameter × wall 120×2
8
thickness)
Flexible element type and size (mm)(outside diameter Dimensions of steel belt wound SSS metal hose:
× length) 147×355
3.2.1 Maintenance methods
Serial Serial
Part Name Part Name
number number

1 20 Assembling bolt
type)

2 Exhaust pipe bracket assembly 21
type)

3 U-shaped bolt-muffler intake pipe 22
type)
4 Hexagon head flange bolt 23 Exhaust pipe bracket assembly
9
5 Tail pipe assembly - with insulation 24 Assembling bolt
6 Exhaust pipe bracket assembly 25 Support assembly-intake pipe
7 Front fixed support - rear processor 26 Base
8 Rear fixed support - rear processor 27 Assembling bolt
Select the catalytic reduction processor

9 Circlip assembly 28
assembly

type)
Rear heat shield assembly - rear

11 Support assembly-intake pipe 30
processor

12 Bracket assembly - post processor 31
type)

13 Band assembly - post-processor 32
type)
14 Hexagonal nut 33 U-bolt
Rear section of intake pipe assembly -

15 34 Bracket-intake pipe
with insulation
16 Circlip assembly 35 Clamp - muffler suspension
17 Circlip assembly 36 Metal hose assembly - with steel mesh
18 Assembling bolt 37 Connecting pipe
19 Bracket assembly - connecting pipe 38 Heat shield
The muffler sounds Internal parts welding open or

Replace muffler assembly
strangely foreign matter entry
The muffler leaks air Shell or end cover cracked Weld or replace muffler assembly
The metal hose leaks air Metal hose fracture Replace metal hose
The exhaust pipe is

The exhaust pipe line cracked Weld or replace the exhaust line assembly
leaking air
Stent fracture Stent fracture Welding or replacement
10
4. Cooling system
4.1 Specifications
Radiator Core size (mm) 928 (width)×880 (height)×42 (thickness)
Intercooler Core size (mm) 740 (width)×592 (height)×51 (thickness)
Use Q/ CAM-192 standard coolant throughout the

Model
Coolant year
Volume (L) About 59
Fan Outside diameter (mm) 750
11
4.3 Structure
12
Serial Serial
Part Name Part Name
number number
Hexagon flange bolt thick rod (standard Hexagon flange bolt thick rod (standard
1 28
type) type)
2 Pressure cover assembly 29 Assembling bolt
3 Hexagon flange nuts 30 Radiator left suspension bracket
4 Expansion box assembly 31 Radiator right suspension bracket
Radiator mount pad assembly(Style

5 Expansion left tank bracket assembly 32
drawing)
6 Expansion tank right bracket assembly 33 Radiator left suspension bracket
Radiator right suspension bracket

7 Hexagonal head screw plug 34
(symmetrical to the left)
8 Backwater steel pipe assembly 35 Hexagon head flange bolt

9 Cushion ring 36
type)
10 Worm drive hose clamp b type 37 Hexagon head flange bolt
11 Radiator degassing hose 38 Washer
12 Return pipe connection 39 Rod cushion assembly
13 Return hose -expansion tank 40 Radiator puller assembly
13
14 Backwater hose - Engine 41 Bolt - pull rod
15 Small worm drive hose clamp 42 Spring washer
16 Hexagonal nut 43 Fan hood assembly
17 Engine degassing hose 44 Radiator assembly

18 45 Intercooler assembly.
type)

19 Hexagonal nut 46
type)
20 Detracheal joint 47 Cushion Assembly - Intercooler (pattern)
21 Assembling bolt 48 Divepipe
Upper left bracket assembly of

22 Tie band 49
intercooler
Upper right bracket assembly of

23 Tie band 50
intercooler
Worm drive hose clamp disc spring

compensation type
Right lower support for intercooler

25 Radiator water outlet rubber pipe 52
(symmetric with left)
26 Radiator water inlet rubber pipe 53 Left lower bracket for intercooler
27 Backstop assembly 54 Hexagon head flange bolt
14
4.4 Intercooler
Serial Serial
Part Name Part Name
number number
Outlet corrugated connecting pipe

1 Worm drive hose clamp 3
assembly of intercooler
2 Corrugated hose assembly 4 Intercooler assembly.
Disassembly and installation of intercooler

assembly.
Remove the intercooler assembly. First remove the

connecting bracket A and bracket bolts with the
radiator assembly.
Remove fan and clutch assembly.

: See fan and fan clutch section.
15
4.5 Radiator and fan hood
Serial Serial
Part Name Part Name
number number
1 Fan hood assembly 2 Radiator assembly
Removal and installation of radiator assembly 9.
Open the pressure cover of the expansion box and the drain screw
plug A to drain the coolant (under special circumstances,
disassemble the radiator outlet pipe B to drain the coolant).
Remove the intercooler assembly.
：see the intercooler section.
16
4.6 Fan and fan clutch
Serial Serial
Part Name Part Name
number number
1 Fan and fan clutch assembly 5 Stud
2 Fan clutch assembly 6 Spring washer
3 Fan Assembly 7 Hexagonal nut

4
type)
Removal and installation of fan assembly [8].

To remove the fan assembly [8], first remove the
upper connecting line 1～7.
17
4.7 Common failures
The radiator collects too much dust Cleaning radiator
Insufficient coolant Add coolant
Engine overheating Blocked cooling channel Clean up obstructed parts
The weather is hot and overloaded Reduce load and speed
Fan clutch malfunction, fan stop Replace fan clutch
Radiators and intercoolers are the components that dissipate heat from the engine and ensure that the engine
works in a normal temperature environment.
The radiator and intercooler are easy to be absorbed and blocked by dust and other sundries in use, which will
affect the heat dissipation. the adsorbate on the external heat dissipation core shall be removed by using
compressed air or high-pressure water flow on a regular basis. the radiator shall clean the internal heat
dissipation pipe on a regular basis.
During maintenance, if coolant is needed, turn on the water drain switch at the lower part of the radiator and
empty the coolant. The coolant volume is about 21L.
When discharging the coolant, open the water inlet cover of the expansion tank, so that the waterway and the
atmosphere are connected, in order to discharge water smoothly.
For the cooling system, it is required to use the coolant that conforms to the local standard, and fill it from the
water inlet of the expansion tank to the upper limit of the water level of the expansion tank. After the vehicle
starts to idle for 5 minutes, if the liquid level is lower than the lower limit of the water level of the expansion
tank, it is necessary to supplement the coolant to the upper limit of the water level.
5 Urea box
5.1. Specifications
Model 1160920-2000
Urea box
Design volume 40L
5.2 Operation before and after disassembly
Operation before disassembly
Engine flameout
When disassembling the urea pipeline, empty the urea solution in the pipeline
When removing the components of the urea system, first pull out the electrical connector
18
After the urea system components are installed, install the electrical connectors
5.3 Assembly drawing of urea tank
19
Serial
Serial
numbe Part Name Part Name
number
r
Urea heating intake manifold - Engine to

1 32 Urea tank hoop assembly
solenoid valve
2 Urea nozzle cooling water intake assembly 33 Hexagon socket head cap screw
3 Intake pipe assembly - chassis tube bundle 34 Hoop pin
20
air inlet to air filter
Urea heating return pipe assembly - urea

4 35 Gasket-band
tank to the engine
Electrically heated urea supply pipe

5 36 Hoop belt nut
assembly - urea tank to urea
Urea nozzle cooling return water pipe

6 37 Bolt for urea tank top retainer
assembly
7 Urea nozzle pipe support 38 lightened spring washer

8 Urea nozzle pipe support 39
type)
9 Urea nozzle pipe support 40 Lanyard - urea tank refill cover
10 Pipeline support 41 Liner - urea tank back plate
11 Hexagon head flange bolt 42 Liner - Urea tank bottom plate
12 Hexagon flange nuts 43 Urea tank welding assembly
13 Assembling bolt 44 Marking for urea tank (Chinese)
14 Tie band 45 O-ring rubber seal for hydraulic gas
O-ring - for sealing the filling port of the

15 Urea tank top retainer 46
urea tank
16 Pad - upper cover of urea tank 47 Urea supply module assembly
Hexagon flange bolt thick rod (standard Sub-assembly of urea supply Module
17 48
type) (Pattern)

18 49 Urea pressure sensor Assembly (Pattern)
type)
19 Hexagon flange lock nut 50 Urea filter core assembly (pattern)
20 Urea tank integrated module Assembly 51 Assembling bolt
21 Hexagon head flange bolt 52 Washer
22 Hexagon flange nuts 53 Hexagonal nut
23 Working platform frame welding assembly 54 Compressed gas filter assembly
Exhaust pipe assembly - urea tank to Compressed gas filter base assembly
24 55
exhaust valve (pattern)
25 Urea heating intake manifold - solenoid 56 Filter Element Assembly for compressed
21
valve to urea tank gas Filter (pattern)
Intake manifold Assembly - Intake valve

to urea tank
Inlet pipe assembly - Air filter to inlet

27 58 Solenoid valve with bracket assembly
valve
28 Urea tank cap assembly 59 Assembling bolt
29 Refill cap assembly for urea tank 60 Solenoid valve with bracket assembly
30 Urea tank assembly 61 Solenoid valve with bracket assembly
31 Urea tank bracket back plate
5.4 Diagnosis and exclusion
Pipeline leak Piping failure Replace pipeline
Urea pump filter blocked Replace the filter of urea pump

Urea pump can't build
Urea tank dirty Cleaning urea tank
pressure
Urea pump damage Replace the urea pump assembly
Urea nozzles do not Urea nozzle damaged Replace the urea nozzle assembly
spray
Clean the urea box every 50,000 km.
Replace urea pump filter every 30000km; according to the urea aqueous solution, the replacement mileage is
appropriately shortened.
22

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Engine accessories maintenance manual

FAW Jiefang Qingdao Automobile Co., Ltd

Rated flow rate (L/h) 480

1.2 Operation before and after disassembly

Operation before disassembly

When removing the fuel line, empty the fuel line

Operation after installation

1.3 Oil tank, bracket, hoop

S/N Part Name Serial Part Name

1 Nut - strap 8 Middle bracket assembly - fuel tank

2 Fastening belt assembly -fuel tank 9 Oil pipe locating mark

Feed pipe assembly - fuel oil strainer to

Return pipe assembly - engine to fuel

5 Bolt1 12 Fuel tank assembly

6 Bolt2 13 Intake pipes and exhaust pipes

7 Front Bracket Assy-Fuel Tank 14 Fuel tank cover assembly

1.3.1 Tightening torque

Part Screwed parts Tightening torque

1 Hoop belt nut 60～70

5、6 Bracket bolts 150～250

1.4 Accelerator pedal

1 Hexagonal nut 3 Electronic accelerator pedal assembly

1.5 Primary fuel filter

1 Oil filter sub-assembly 5 Fast connector

2 Upper cover assembly 6 Water level alarm assembly

3 Fuel filter main housing assembly 7 Oil filter core assembly

4 Water cup assembly

1.5.1 Tightening torque

Part Screwed parts Tightening torque

6 Drain bolt assembly About 1.5

Part Coating position Prescribed lubricant Number

1.5.3 Special tools

Part Tool Title Shape Use

1.6 Common failures

Fault phenomenon Reason analysis Elimination method

Replace the gasket with a new

Replace with a new component

1.7 Use and maintenance

Clean the fuel tank every 50,000 km.

Type Paper dry air filter

Inlet diameter(mm) 212×160

Outlet diameter(mm) 160

2.2 Work before disassembly and after installation

Work before disassembly

Tilt the cab forward

Operation after installation

The cab falls back

1 Assembling bolt 24 Hexagonal nut

2 Air cleaner assembly 25 Large washer

3 Secondary filter element assembly 26 Shock absorber bracket assembly

4 Main filter element assembly 27 Rubber gasket

Connect base assembly - air

Hexagon flange bolt thick rod (standard

Cross Recessed Pan Head Tapping Screw

8 Air inlet pipe(pattern) 31 Assembling bolt

9 Heat shield B(pattern) 32 Connecting hose assembly-air filter

Worm-driven hose clamp assembly

11 Hexagonal nut 34 Inlet trim panel assembly(pattern)

13 Heat shield A(pattern) 36 Spring washer

14 Reinforced hose clamp(pattern) 37 Spring washer

15 Shock absorber bracket assembly 38 Spring washer

16 Reinforced hose clamp(pattern) 39 Large washer

17 Reinforced hose clamp(pattern) 40 Assembling bolt