DongFeng EQ1030T47D-820 User manual

EQ1030T47D-820
Light Commercial Truck
Service Manual
PEOPLE'S REPUBLIC OF CHINA
DONGFENG AUTOMOBIL CO.,LTD.
2006, 6

TOC
General
QD32 Engine
Clutch
Transmission
Front Suspension
Rear Axle & Rear Suspension
Propeller Shaft & Differential
Steering System
Brake System
Cab & Frame
Electric System

General
GL
TOC
Preventive Measures ..................................................................................GL-2
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

General
GL-1
General
This manual mainly contains maintenance and service method of the DONGFENG STAR EQ1030T47D-820
light commercial truck.
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.
2006,6
DONGFENG STAR Engine Equip
EQ1030T47D-820 CYQD32 diesel
engine
COE, single row, with front independent suspension,
power steering, front disc and rear drum brake

General
GL-2
Preventive Measures
See preventive measures below to get safe operation and suitable mainte-
nance 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, refrig-
erant 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.

General
GL-3
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 mainte-
nance, 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 help-
ful information are provided.

General
GL-4
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 mainte-
nance 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
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 envi-
ronment for a long time, it will be necessary to do the following maintenance more frequent.
Maintenance Items Maintenance Intervals （× 1000km）
5 101520253035404550556065707580
Replace lubricant ★RRRRRRRRRRRRRRRR
Replace oil filter cartridge
★RRRRRRRR
Maintenance Items Maintenance Intervals （× 1000km）
1 1020304050607080
Exhaust device and tighting of other nuts I
Drivebelt IIIII
Engine coolant R R
Cooling system I I I I
Fuel pipeline I I
Airfilter CCCRCCCR
Air inlet and outlet valve A A A A A
Fuel spray nozzle 请看注意 （1）
Idle speed I I I I I

General
GL-5
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 Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40
Check working condition of clutch ☆★★★★★★★★★★
Check clutch pedal free play ☆★★★★★★★★★★
Check hydraulic pipe line and pump for leakage ☆★★★★★★★★★★
Transmission
Maintenance Items Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40
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 Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40
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 ★
Steering system
Maintenance Items Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40
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 ☆★★★★★★★★★★

General
GL-6
＊If the ball pin dust cap is damaged, replace it immediately, because it may damage the ball pin and
cause danger in driving.
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 Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40
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 ★
Propeller shaft
Maintenance Items Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40
Check shaft connecting part for looseness ☆★★★★★★★★★★
Check tightening condition of spider bearing of propeller shaft ☆★★★★★
Check propeller shaft splines for wear and damage ☆★★★★★
Steering system
Maintenance Items Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40

General
GL-7
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.
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)
Axle & wheel
Maintenance Items Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40
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 Maintenance Intervals( ×1,000km）
△4 8 12 16 20 24 28 32 36 40
Check the connecting part tightening conditions of cargobody to
frame ☆★★★★★
Check thelongitudinal and cross member of the cargo body for loose-
ness 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) ☆★★★★★
Replace Items Replace Intervals (Year)
123456789101112
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 ★★★★★★★★★★★★

General
GL-8
☆—Running-in maintenance lubrication item
★—Normal driving lubricating item
Main Adjusting Data
Lubricant
Capacity Data
Place of lubricating Lubricating interval mileage （× 1,000km）
△4 8 12 16 20 24 28 32 36 40
Slip yoke of steering drive shaft and spider bearing ☆★★★★★
Door hinge ☆★★
Door lock, glass regulator, odometer flexible shaft ☆★★
Hub bearing ☆★★
Adjusting Items Standard
Air valve clearance (cold) Inlet valve 0.35mm
Exhaust valve 0.35mm
Oil pressure of idling engine 69~100kPa
Oil pressure of normal run engine 196~490kPa
Water temperature of normal run engine 80~95 ℃
Tension grade of alternator belt 10~15mm
Free travel of clutch pedal 25~40mm
Free play of brake pedal 20~25mm
Steering wheel free play 10°
Toe-in 0~2mm
Place Lubricant Type Grade
Engine lubricating system Engine oil 5W/20 API CF-4
Engine cooling system Antifreeze, anti-rust coolant
Transmission Manual operation special oil 75W/90 API GL-4
Main reductor Industrial gear oil 75W/90 API GL-5
Steering gear Power steering fluid ATF-2
Clutch & brake system Synthetic brake liquid 901-4 DOT4
Bearing and ball pin Li-base lubricant grease 2, 3# SH0535-93
Part Capacity (L)
Fuel tank 65
Engine lubricant system 6.5
Water tank and cooling system 13 to full
Transmission 2.7
Main reductor 6.5~5.0 to overflow
Steering gear to the MAX
Brake system to the MAX

General
GL-9
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.
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.
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 tem-
perature 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:
0# Light diesel oil Local temperature above 4 ℃
10# Light diesel oil Local temperature above -5 ℃
20# Light diesel oil Local temperature between -5 ℃~ -14 ℃
35# Light diesel oil Local temperature between -14 ℃~ -29 ℃
50# Light diesel oil Local temperature between -29 ℃~ -44 ℃

General
GL-10
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 con-
necting part 88~108
Engine rear mounting bracket and cushion connecting
part Follow EQB-37-1999
Transmission bolt and rear mounting bracket connect-
ing part Follow EQB-37-1999

General
GL-11
Transition output shaft and propeller shaft connecting
part 69~78
Transition control flexible shaft fixed bracket and lon-
gitudinal member connecting part 13~16
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 connect-
ing part 30~41
Engine front mounting cushion nut 46~56
Engine and clutch housing conneting part 39~49
Engine exhaust pipe and vehicle exhaust pipe connect-
ing part 51~65
Steering wheel locking nut 29~39
Steering gear and steering gear drive shaft universal
knuckle fork connecting nut 25~29
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 88~137
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 78~98
Steering knuckle and lower cross arm ball head fixed
nut 118~191
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 60~72
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 connect-
ing part 21~25
Fuel tank bracket and frame connecting part 21~28
Fuel tank band fixed bolt part 20~23
Part Tightening torque (N.m)

General
GL-12
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.
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
Part Tightening torque (N.m)

Clutch
CL
TOC
Precaution and Preparation...................................................................... CL-1
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

Clutch
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

Clutch
CL-2
Clutch System
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
11.Spacer
12.Rear oil pipe assy
13.Clutch rear bent pipe bracket
14.Hose assy
15.Gasket
16.Clutch slave pump assy

Clutch
CL-3
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 cir-
cles, 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.

Clutch
CL-4
Clutch Control System
Clutch master pump
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
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