Drive shaft maintenance manual

Jiefang
CA3250P25K15L3T1E5A80
Flat diesel dump truck
Maintenance manual
Transmission shaft

FAW Jiefang Qingdao Automobile Co., Ltd

November 2020
 Drive shaft maintenance manual

Contents
1. Specification and location map.........................................................................................................................................1
1.1Specifications...................................................................................................................................................................1
1.2 Parameters......................................................................................................................................................................1
1.3 Location map..................................................................................................................................................................1
2. Structure............................................................................................................................................................................1
2.1 Intermediate axle drive shaft..........................................................................................................................................1
2.2 Rear axle drive shaft.......................................................................................................................................................2
3.Work before disassembly and after installation.................................................................................................................3
4. Intermediate axle drive shaft............................................................................................................................................3
4.1 Decomposition sequence................................................................................................................................................3
4.2 Assembly sequence.........................................................................................................................................................4
4.3 Maintenance standard.....................................................................................................................................................4
4.4 Tightening torque............................................................................................................................................................4
4.5 Lubricating grease..........................................................................................................................................................4
5 Maintenance method..........................................................................................................................................................4
6. Rear axle drive shaft.........................................................................................................................................................6
6.1 Decomposition sequence................................................................................................................................................6
6.2 Assembly sequence.........................................................................................................................................................6
6.3 Maintenance standard.....................................................................................................................................................6
6.4 Tightening torque............................................................................................................................................................7
6.5 Lubricating grease..........................................................................................................................................................7
6.6 Maintenance method.......................................................................................................................................................7
7. Typical fault analysis........................................................................................................................................................7
8. Use and maintenance........................................................................................................................................................8
 Drive shaft maintenance manual
1. Specification and location map

1.1Specifications
Items Axle shaft Rear axle shaft

Transmission shaft specification Universal joint pin φ70 Cross shaft φ 52

Rated torque（Nm） 25000 12000

Limiting angle of transmission shaft( °) 22 36

Rotary diameter of transmission shaft

200 180
assembly(mm)

1.2 Parameters

Dimension of shaft tube of middle axle transmission

133*5
shaft (diameter x wall thickness)

Number of universal joints 2

Number of transmission shafts 1

1.3 Location map

2. Structure

2.1 Intermediate axle drive shaft

8
7
6
5
3 4

1 2
10

Number Part Name Serial Part Name

1
 Drive shaft maintenance manual
numbe
r

1 I-Type non-metal hexagon lock nut 6 Dust cover and seal assembly

2 Hexagon head flange bolt 7 Splined bush

3 Flange fork 8 Straight through grease nozzle

4 Cross shaft assembly grease fitting 9 Axle tube

5 Spline shaft fork 10 Welding fork

2.2 Rear axle drive shaft

9
8
7

6
5
4
1 2 3

Number Name Number Name

1 I-Type non-metal hexagon lock nut 6 Dust cover and seal assembly

2 Hexagon head flange bolt 7 Splined bush

3 Flange fork 8 Straight through grease nozzle

4 Cross shaft assembly grease fitting 9 Welding fork

5 Spline shaft fork

2
 Drive shaft maintenance manual
3 .Work before disassembly and after installation
Work before disassembly

Engine stalling.

Place wheel chocks。

Warning

★The wheel block should be fastened to prevent the car from moving.

★Before all operations are completed, do not take away the wheel block

Operation after installation

Close the wheel stop.

4. Intermediate axle drive shaft

4.1 Decomposition sequence

Serial
Number Part Name Part Name
number

1 I-Type non-metal hexagon lock nut 5 Cir clip

2 Hexagon head flange bolt 6 Straight through grease nozzle

Spline shaft fork and universal joint

3 7 Flange fork
assembly

Intermediate axle drive shaft and

4 8 Cross shaft assembly grease fitting
universal joint sub assembly

3
 Drive shaft maintenance manual
4.2 Assembly sequence

In the reverse order of disassembly

4.3 Maintenance standard

Maintenance projects Standard value: Limit value Correction methods

Dynamic balance test of

Dynamic balance test of
transmission shaft 150g.cm 150g.cm
transmission shaft assembly
assembly

Universal joint rotation Universal joint rotation

5-15N·m 5-15N·m
moment detection moment detection

4.4 Tightening torque

Part Screwed parts Tightening torque

2 Hexagon head flange bolt 180 Nm 220 Nm

4.5 Lubricating grease

Part Filling position Prescribed lubricant Number

Fill until oil comes out from all

Lithium - based lubricating
Cross shaft assembly of the cutting edge of the four
8 grease for all - weather
grease nozzle universal joint needle roller
vehicles
bearings.

Lithium - based lubricating

Spline pair grease
6 grease for all - weather 150g
nozzle
vehicles

5Maintenance method

Removal and installation of axle shaft

When removing the middle axle transmission shaft, first use a

wrench to loosen the connecting bolt [2] between the middle
axle transmission shaft flange fork and the middle axle input
flange, and then remove the bolt.

[2]

4
 Drive shaft maintenance manual

Then use a wrench to loosen the connection bolts [2] between

the axle shaft flange fork and the transmission output
flange，remove the bolts.

Intermediate axle drive shaft Installation in reverse order.

[2]

Check whether the cross shaft and needle bearing assembly

are worn or damaged.

Replace the cross shaft assembly or transmission shaft

assembly as required.

Check the drive shaft appearance and sliding spline.

Rotate the drive shaft back and forth in two opposite

directions，and there should be no noticeable gaps; Check the
spline for excessive wear; Check the shaft for cracks,
deformation, or excessive wear.

Replace the transmission shaft assembly as required.

When assembly, align with the arrow mark.

During assembly, align the marks the center line of the bearing
hole on the spline shaft fork is in the same plane as that welded
on the other end of the shaft spline sleeve.

5
 Drive shaft maintenance manual
6. Rear axle drive shaft

6.1 Decomposition sequence

Serial
Number Part Name Part Name
number

1 I-Type non-metal hexagon lock nut 5 Cir clip

2 Hexagon head flange bolt 6 Straight through grease nozzle

Spline shaft fork and universal joint

3 7 Flange fork
assembly

Rear axle drive shaft and universal joint

4 8 Cross shaft assembly grease fitting
sub assembly

6.2 Assembly sequence

In the reverse order of disassembly

6.3 Maintenance standard

Maintenance projects Standard value: Limit value Correction methods

Dynamic balance test of

100g.cm 100g.cm Dynamic balance again
transmission shaft assembly

Universal joint rotation

5-15N·m 5-15N·m Replace the snap ring
moment detection

6
 Drive shaft maintenance manual
6.4 Tightening torque

Part Screwed parts Tightening torque

2 Hexagon head flange bolt 180 Nm 220 Nm

6.5 Lubricating grease

Part Filling position Prescribed lubricant Number

Fill until oil comes out from all

Lithium - based lubricating
Cross shaft assembly of the cutting edge of the four
8 grease for all - weather
grease nozzle universal joint needle roller
vehicles
bearings.

Lithium - based lubricating

Spline pair grease
6 grease for all - weather 120g
nozzle
vehicles

6.6 Maintenance method

Disassembly and installation of rear axle drive shaft

See removal and installation of axle shaft

7
 Drive shaft maintenance manual
7 Typical fault analysis
Fault phenomenon Reason analysis Elimination method

Transmission shaft deformation Replace the transmission shaft

The remaining unbalance of the

Re-conduct dynamic balance
transmission shaft is too large

Spline fitting clearance is too large Replace the transmission shaft

Abnormal sound and The connecting bolts of transmission After careful inspection, tighten the loose
vibration of driving shaft, transmission and drive axle are bolts according to the specified torque and
shaft loose replace the damaged parts

Transmission shaft cardan loose,

Replace damaged parts
ablation or excessive wear

Check whether the grease is sufficient and

Bad lubrication
whether the lubrication path is unobstructed

8. Use and maintenance

Maintain the grease level and check the grease level of the cross shaft assembly and spline pairs periodically
according to the maintenance manual. Lack of grease causes early wear of the moving parts and severe
ablation；
When grease is added, the rotary transmission shaft makes the cross shaft and spline pair grease nozzle face

downward, and the grease is added in the required quantity with the oil gun.