DongFeng DFA1063DJ10-301 Service Manual Download

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DONGFENG DFA1063DJ10(14)-301/303

SERVICE MANUAL

DONGFENG AUTOMOBILE CO., LTD.

September. 2006

Summary of Contents for DFA1063DJ10-301

Page 1: ...DONGFENG DFA1063DJ10 14 301 303 SERVICE MANUAL DONGFENG AUTOMOBILE CO LTD September 2006 ...

Page 2: ...INDEX General Principles Clutch Gearbox Propeller Shaft Steering System Front Axle Rear Axle Suspension System Brake System Cab Electric System ...

Page 3: ...nciples GL 1 Operational Instruction GL 2 Standard Terms GL 2 Standard Tightening Torque GL 2 Maintenance Rule GL 3 Recommended Fuel and Lubricant GL 6 Protective Measures while Repairing GL 8 Cleaning GL 9 Generic Inspection GL 9 Trouble Analysis GL 10 ...

Page 4: ...k Note This is very important Due to continuous improvements on our vehicles maybe there are some instructions in the manual that do not accord with the actual vehicles Maintenance method varies with different skill level methods tools and available parts that serviceman adopts Any serviceman should firstly take into consideration no harm personal safety and vehicle safety when working As for the ...

Page 5: ...he specified repair limit Wear limit It means that if a component is overworn or exceeds its wear limit it must be replaced Unit Legal measure units are used in this manual Standard Tightening Torque To assure the safety and reliability of key vehicle parts this manual makes specific prescriptions to the tightening torque of the bolts and other fasteners on those parts As for the bolts and other f...

Page 6: ...and move reliability Never prolong the intervals Dongfeng Cummins Diesel Engine Maintenance Item Maintenance Mileage Interval 1 000km 4 8 12 16 20 24 28 32 36 40 44 48 80 Clean engine assembly Check acceleration capability and decelerability Check exhaust status Check the leakage of eninge lubricant Check the cleanness and reserves of lubricant Check the leakage of fuel Check the leakage in coolin...

Page 7: ...rbox Maintenance Item Maintenance Mileage Interval 1 000km 4 8 12 16 20 24 28 32 36 40 44 48 80 Clean gearbox and vent plug Check the oil reserves in gearbox Check oil leakage of gearbox Replace gearbox lubricant Check the looseness of the linking parts of the con trol mechanism Check the working conditions of the bearings in gearbox Disassemble and check gearbox Suspension System Maintenance Item...

Page 8: ...ar Clean steering gear Check free travel and working conditions of hand wheel Check the fastening conditions of the ball heads of steering cross rod and tie rod Check fastening conditions of steering mechanism and its brackets Check fastening conditions of steering arm and steer ing knuckle arm Check and adjust front wheel toe in Check front wheel alignment Check and adjust steering gear Disassemb...

Page 9: ...ard CG 4 SH 15W 40 Ideal standard CH 4 SJ 15W 40 Check the fastening conditions of brake back plate Check the wearing of brake drum and shoe replace while necessary Check the working conditions of air compressor Other Maintenance Item Maintenance Mileage Interval 1 000km 4 8 12 16 20 24 28 32 36 40 44 48 80 Check battery liquid reserves add while necessry Check the proportion of battery liquid Che...

Page 10: ...mmend to use generally used lithium grease for the lubricating points on hubs and chassis frame Shock absorber oil Recommend to use specially used shock absorber oil Clutch boosting liquid Recommend to use DOT 4 compounded braking liquid Different classes of braking liquid can not be used together Note Braking liquid made by different manufacturers can not be used together Engine antifreeze liquid...

Page 11: ...n repairing electric circuit the negative pole should be disconnected 5 The jacks and brackets used should be strong enough for the load acting on them Method of mounting brackets is as the sketch map The supporting points of front axle for mounting jacks is as the sketch map The supporting points of rear axle for mounting jacks is as the sketch map Gearbox 4 2 Rear axle Add till the oil overflow ...

Page 12: ...rts Don t use mineral oil for the cleaning Use alcohol or clean cloth to remove the mud Oil duct Make a metal wire to get through the oil duct to ensure it is not jammed Wash the oil duct with cleaning solution with high pressure nozzle Antirust After removing the oil grease on the parts clean grease should be applied to prevent the rusting of the parts General Inspection Check parts and component...

Page 13: ...of disassembling the steering gear rashly then decide whether the trouble belongs to the steering gear or to the connection mechanism When disassembling the part to find the cause of the trouble proceed systematically and start from easy problem It is a very important way to find out the cause of the trouble according to the manifestation of the trouble such as abnormal noise vibration and failure...

Page 14: ...or gear troubled oil insufficient or deteriorate Wheel hub bearing troubled grease insufficient or improper Over low tyre pressure Noise Transmission troubled Reductor gear troubled Propeller troubled Noise when run on road bend Differential gear troubled Noise when brake Brake troubled Too heavy vibration Front and rear leaf spring troubled Shock absorber troubled Propeller shaft troubled Engine ...

Page 15: ...sufficient steering angle Steering system troubled Front axle troubled Abnormal gear shift Difficult gear shift Abnormal clutch disengagement Transmission troubled Transmission handling mechanism troubled Gear disengaged Transmission troubled Transmission handling mechanism troubled Abnormal braking operation Weak braking Brake system troubled Overwear of tyres Hub bearing clearance too large Brak...

Page 16: ...Clutch CL Table of Contents Main Parameter CL 1 Clutch Mechanical System CL 2 Adjustment of Clutch Pedal CL 3 Clutch Cover and Flywheel CL 6 ...

Page 17: ... pressure sys tem After clean the clutch pressure plate dry it with the suction cleaner not the compression air Bolt install hole size Distributing diameter mm Φ 379 Aperture mm Φ 10 5 0 27 Number of holes 8 4 pairs Positioning pin hole size Distributing diameter mm Φ 384 Aperture mm Φ 9 5 0 061 0 025 Φ 7 9 0 061 0 025 Number of holes 2 Angle between positioning hole and installing bolt hole 10 Fr...

Page 18: ...lutch Control Mechanism 1 Clutch pedal bracket assy 2 Lower fixed plate pedal bracket 3 Clutch pedal welding assy 4 Protective sheath pedal 5 Clutch pedal shaft 6 Return spring clutch pedal 7 Bush pedal assy 8 Pin 9 Clutch master pump assy ...

Page 19: ...lease fork for wear damage or erode and replace if necessary Bearing lubricating Make use of the recommended lubricant for the connecting surface and the attrition surface of bearing and fork Note Overmuch lubricant may cause clutch driven disc damaged 1 Clutch master pump assy 2 Front oil pipe assy clutch master pump to slave pump 3 Straight joint 4 2nd front oil pipe assy clutch master pump to b...

Page 20: ... disc 4 Friction disc 5 Damping fin 6 Driven disc clamping plate 7 Driven disc 8 Driven disc rivet 9 Wave spacer 10 Wave spacer rivet 11 Disc hub set 12 Spline disc 13 Damping spring1 14 Damping spring2 15 Rear damping disc 16 Half ring pressure board 17 Catch plate 18 Damping spring idle speed 19 Spring spacer 20 Guard shield ...

Page 21: ... disc to the top of the dia phragm If the height is not in the range of the specific range you need to replace the pressure plate Shake the pressure plate gently listening and check the wear or dam age of the diaphragm supporting ring Or you can knock the rivet head gently to find if there is cracks Replace the pressure plate if necessary Check the surface of the pressure plate for any ablation or...

Page 22: ...ch Cover and Flywheel 1 Drive spacer 2 Rivet cover 3 Spacer sleeve 4 Rivet diaphragm spring 5 Supporting disc 6 Diaphragm spring 7 Clutch pressure plate 8 Cover 9 Balance rivet 10 Rivet 11 Stop spacer 12 Spring washer ...

Page 23: ... the control mechanism you have to make sure that the travel of the release bearing is 2 3mm and the efficient travel of the release bearing should be not less than 10mm 2 Notice Pay attention to match the proper torque of the engine during using which is to assure the certain repertory coefficient The friction plate mustn t be contaminated with oil stain during using The vehicle should not be ove...

Page 24: ...n MT Table of Contents Maintenance Standard MT 1 Trouble Shooting MT 2 Construction MT 4 Transmission Disassembly MT 8 Check MT 10 Assemble Point MT 11 Transmission Control System MT 14 Check and Adjustment MT 15 ...

Page 25: ...ns mission top cover Clearance between gear select rocker block and gear shift lever block slot 0 1 0 4 0 8 Tooth space between control shaft and gear shift lever spline 0 05 0 11 0 5 Trans mission upper cover Clearance between transmission fork shaft and transmission fork hole 0 140 0 101 0 25 Clearance between end face of the reverse gear fork and ring groove 0 5 0 8 Not drop Clearance between e...

Page 26: ...t 200 300 Reverse gear shaft locking plate bolt 20 26 Oil drain scew and filler port screw 120 140 Propeller shaft connecting bolt and nut 215 245 Midship mounting bolt and nut 160 220 Trouble Cause Correction Abnormal sound or noise Viscosity of lubricating oil too low Lubricating oil insufficient Gear teeth cracked or worn out clearance too large Bearing worn out or broken Engaging position of s...

Page 27: ... spring broken or fatigue The clearance of gear too large Connecting teeth or sleeve back taper failure Sliding part or end face of sliding sleeve worn Bearing worn cause the axial running Flange locking nut loosened Check and adjust or replace it if it is twist Disassemble and replace worn parts Replace Adjust the clearance or replace gear Check replace Replace shaft sleeve Replace bearing Tighte...

Page 28: ...r intermediate shaft 11 Sealing ring intermediate shaft front bearing cover 12 Cover board power take off hole 13 Cover board gasket spacer power take off hole 14 Square end conical screw plug 15 Transmission housing 16 Rear bearing cover gasket spacer output shaft 17 Rear bearing cover output shaft 18 Oil sealing odometer driven gear 19 Flexible shaft joint odometer 20 O sealing ring flexible sha...

Page 29: ... 3rd gear synchronizer 19 Balking ring assy 2nd 3rd gear synchronizer 20 Balking ring 2nd 3rd gear synchronizer 21 Lockpin 2nd 3rd gear synchronizer 22 Slide gear sleeve 2nd 3rd gear 23 Transmission output shaft 24 2nd gear 25 Needle bearing 2nd gear 26 Thrust clip 1st gear 27 Thimble 28 1st gear 29 Needle bearing 1st reverse gear 30 Slide gear sleeve 1st reverse gear 31 Fixed tooth holder 1st rev...

Page 30: ...ate shaft 6 4th gear intermediate shaft 7 3rd gear intermediate shaft 8 2nd gear intermediate shaft 9 Half round key 10 Transmission intermediate shaft 11 Vehicle bearing 12 Snap ring 13 Nut lockpin 14 Roung nut 15 Outside thrust shim reverse gear 16 Inside thrust shim reverse gear 17 Vechile bearing 18 Needle bearing spacer sleeve reverse gear 19 Reverse gear 20 Reverse gear shaft 21 Reverse gear...

Page 31: ...15 Gear selecting rotating arm assy 16 Switch assy 17 Sealing ring 18 Steel ball 19 Gasket spacer cover 20 Transmission upper cover 21 Gasket spacer upper cover 22 Spacer 23 Vent plug assy 24 Guide block 1st reverse gear 25 Locking gear shift fork shaft spring 26 Steel ball 27 Gear shift fork shaft 1st reverse gear 28 Gear shift fork 1st reverse gear 29 Straight pin interlock 30 Gear shift fork sh...

Page 32: ...verse speed switch and separate the parking brake steel wire and rocker 6 Disassemble transmission control system 7 Remove the return spring and dowel pin of the clutch s slave cylinder then put the clutch s slave cylinder assem bly onto frame safety 8 Remove wire and tube 9 Disassemble transmission with transmission jack and steel wire Disassembly 1 Remove transmission upper cover assembly gasket...

Page 33: ...embly and all the parts in front of synchronizer in turn from mainshaft Take off 1st and reverse speed gear from rear end of mainshaft depress the thrust ring locking pin with screw driver turn the thrust ring and remove it Note When removing the thrust ring avoid the rebound of the locking pin by the spring 5 Remove reverse speed gear shaft lock plate pull out the reverse speed gear shaft with ex...

Page 34: ... gear out with press machine then take off another snap ring press the other gears and spacers out with press machine in turn Check 1 Check the backlash of each pair of gears Standard dimension 0 15 0 26mm Service limit 0 50mm 2 Check the axial clearance of each gear The axial clearance of mainshaft 2nd speed gear Standard dimension 0 05 0 37mm Service limit 0 40mm The axial clearance of mainshaft...

Page 35: ...the bulging part of sliding sleeve face forward Make sure that the axial clearances of each gear correspond to standard axial clearance Sub assembly assemble 1 Mount the countershaft assembly into countershaft hole of transmission assembly in correct direction 2 Align the countershaft at countershaft front bearing hole of front end of casing cover the front bearing tap the bearing outer ring regul...

Page 36: ...opper rod to make the bearing get close the shoulder of main shaft spline cover the drive gear of speedometer and spacer then put the snap ring at bearing outer ring 5 Press the rear bearing into input shaft assemble the snap ring and the steel ring of bearing outer ring put the mainshaft front bearing into inner hole 6 Put the input shaft into casing front end bearing hole align the mainshaft fro...

Page 37: ... install disk like washer tighten the locking nut Tightening torque 196 245Nm Assemble of the assembly Before assemble transmission onto truck make sure that the corresponding parts is tightened 1 Install transmission and bracket as a assembly into truck with transmission jack and steel wire make sure that input key into clutch driven disc hub spline 2 Install clutch booster or clutch slave cylind...

Page 38: ...ushing 6 Selector rocker and shift sleeve sets 7 Sheathing 8 Selector return spring 9 Buffer shell 10 Flexible shaft and rocker shaft bracket sets 11 Shift and selector flexible shaft with ball joint assy 12 Flexible shaft clip board 13 Upper bracket double hose clip 14 Shift selector flrxible shaft clip board 15 Flexible shaft bracket assy 16 Pin 17 Selector rocker 18 Pin needle bushing ...

Page 39: ...e the exteriors of flexible shaft and any sealing parts Adjustment of selective shift flexible shaft 1 Fit the ball joint assembly at the connecting end of selective shift flexible shaft and gear shift then push the flexible shaft to the bottom to adjust the ball joint and big nut the dimension of A should meet the requirement A 185 1mm 1 Ball joint 2 Adjusting nut 3 Locking nut 2 Install the rubb...

Page 40: ...haft clip After finished the adjustment tighten the adjusting nut 1 Ball joint 2 Adjusting nut Installation of flexible shaft The selective shift flexible shaft assembly adjusted according to the above way can be assembled on the truck 1 Loosen the big nut of front end let the flexible shaft go through the bracket and the dirt boot plate and then tighten the big nut 2 Connect the ball joint assemb...

Page 41: ...rts pay attention to assemble direction it should not be crooked Lubrication normally Lubricating grease need not be used in flexible shaft control system If the noise is found in operating the flex ible shaft control system or it is difficult to operate the control system it is necessary to turn over the cab to check whether the lubricating grease is sufficient in dirt boot of shift level support...

Page 42: ...PR Table of Contents Technical Parameter PR 1 Maintenance Standard PR 1 Tightening Torque PR 1 Trouble Analysis PR 1 Propeller Shaft PR 2 Intermediate Propeller and Center Bearing PR 3 Propeller Shaft Maintenance PR 3 ...

Page 43: ...g 0 1 Axial clearance of center bearing 0 5 Center bearing bearing seat inside hole sur face worn 0 05 ItemItem Tightening Torque Propeller shaft flange fork connecting nut 90 110 Center bearing locking bolt and nut 901 10 Trouble Cause Method Abnormal vibration in the running Connecting bolts on the propeller shaft loosely Tighten bolts or nuts Propeller shaft vibration Propeller shaft has not be...

Page 44: ...cture 1 Flange fork 2 Bolt 3 Cross shaft needle bearing assy 4 Dust collar 5 Cross shaft 6 Grease nipple 7 Snap ring for holes 8 Slip york assy 9 Grease fitting 10 Slip york oil seal 11 Oil seal spacer 12 Oil seal cover 13 Propeller shaft assy ...

Page 45: ... point of the propeller shaft for its radial runout 1 Flange fork 2 Cross shaft needle bearing assy 3 Dust collar 4 Cross shaft 5 Grease elbow 6 Snap ring for holes 7 Intermediate propeller shaft assy 8 Washer center bearing seat 9 Center bearing bracket assy 10 Upper cover board center bearing 11 Oil seal center bearing 12 Bearing seat center bearing 13 Bearing center bearing 14 Flange driving co...

Page 46: ... the radial runout again if it still beyond the limit value replace the propeller shaft 5 Road tests Appearance check Check the surface of the propeller shaft for any cracks or pit If there were replace the propeller shaft Disassembly and assembly Make marks on the flange disc and remove the propeller shaft from the end of the rear axle Pull the propeller shaft out from the power train and plug th...

Page 47: ...value replace the propeller shaft Check the axial freedom of the spider shaft If the axial freedom of the spider shaft is beyond the limit value you have to replace the spider shaft assembly Disassembly Disassemble the spider shaft 1 Make marks on the propeller shaft and flange fork 2 Remove the snap ring ...

Page 48: ...ake marks on the dismantled parts and you may not change their original position when reassembling Assembly Spider shaft 1 Install the spider shaft bearing apply some grease on the surface of the bearing inside face Never miss the needle of the needle bearing when assembling 2 Select a snap ring to make the spider shaft among the required axial clearance and install it The thickness of the selecte...

Page 49: ...der shaft Maintain Replace of the front oil seal Note The adjusted spacer is used for the driveline After the disassembly of the flange it is necessary to adjust the pretightening force of the bearing so the main retarder needs to be repaired 1 Remove the propeller shaft 2 Loose the end face nut 3 Remove the connecting flange 4 Remove the front oil seal ...

Page 50: ...t 7 Assembly the propeller shaft Disassembly and Assembly Disassemble Remove the propeller shaft After removing the propeller shaft plug the output port of the transmission by plug Remove the axle housing half axle Note Don t damage the spline sleeve flange fork and front oil seal when removing the propeller shaft Assemble Fill with recommended gear lubricant ...

Page 51: ...Steering System ST Table of Contents Check ST 1 Steering Wheel and Steering Column ST 2 Power Steering Hydraulic pressure System ST 5 Steering gear ST 6 Trouble Analysis ST 7 ...

Page 52: ...eal spacer and O ring Avoid using the used spacer oil seal and O ring when assembling After assembly you must have a test run Check Check the free travel of the steering wheel Measure the free travel of the steering wheel when it is set on the cen ter Free travel 35mm If the measured value isn t in this range check the the steering gear clearance and the ball pin Check the center position of the s...

Page 53: ...7 Saucer spring washer 8 Pressed nut 9 Adjustor wrench assy 10 Washer fix wrench 11 Bolt fix wrench 12 Return spring 13 Distance limit spacer sleeve 14 Steering shaft 15 Steering universal joint fork 16 Spider 17 Spider needle bearing assy 18 Steering universal joint fork with spline shaft 19 Oil sealing sliding fork 20 Oil sealing cap sliding fork 21 Steering sliding fork assy 22 Grease nipple sh...

Page 54: ...f force When assemble the steering cross shaft you must check if the locking bolt and the sunk part is aligned Disassembly and Assembly When do the disassembly and assembly you have to unlock the steering lock by key Assure the surface of the spring lock ring is under the shaft Before insert the shaft into the sleeve first install the spring lock ring Assemble the spring lock ring on the upper hal...

Page 55: ...heck its moving condition Front rear 6 Up down L3 15mm Check If the steering wheel can t be turned flexibly please check the steering column by the following steps and replace the corresponding wearing parts Check the steering column bearing for any damage or wearness and lubricate the bearing with proper grease Replace the total steering column if necessary Check the steering column sleeve for di...

Page 56: ...embly 2 Elbow assembly inlet oil 3 Upper bracket 4 Elbow assembly outlet oil 5 Bracket 6 Clip 7 Clip 8 Oil pump 9 Bolt joint of the oil pump 10 Joint inlet oil tubing 11 Jacket 12 High pressure hose assembly 13 Hose 14 Hose steering gear to oil reservoir 15 Oil reservoir assembly steering ...

Page 57: ...ear drain off the remain oil in the oil pump and the oil reservoir idle the engine and turn the steering wheel left and right to the limit for several times till there is not oil flowing out 3 Tighten the oil outer bolt keep it clean and avoid dirt entered 4 Fill with new hydraulic pressure oil 5 Idle the engine turn the steering wheel left and right to its limit for several times until there is n...

Page 58: ...r oil pressure in the oil pump Replace oil pump 8 Vehicle overload too much Reduce load One way heavey steer ing 1 Tire pressure of one side isn t enough Inflating 2 Only one direction of the steering gear leak out too much Repair the steering gear 3 The rotary valve isn t in the nuetral position 4 The fixed pressure of left or right can t be set up Replace sealing part Heavey steering when quickl...

Page 59: ...steering gear Adjust the side cover bolt 4 Oil level of the oil reservoir is lower than the lowest mark Add oil 5 Front axle leaf spring fixed bolt loosed Tighten 6 Steering universal joint locking bolt loosed Tighten Steering wheel return failed 1 Insufficient tyre pressure Inflating 2 Too tight fit of the front axle parts Adjust 3 Improper alignment of the front wheel Steering wheel return too q...

Page 60: ...mbly of the Front brake FA 2 Maintenance FA 3 Assembly and Adjustment FA 4 Trouble Analysis FA 5 Appendix 1 Lubricanting Parts and Lubricant FA 7 Appendix 2 Tighten Torque of the Bolts and Nuts FA 7 Appendix 3 Main Adjusting Data and Maintaining Standard FA 8 ...

Page 61: ...ckle 6 Lower bush 7 King pin blanking cover assy 8 Washer 9 Screw king pin blanking cover 10 Grease nipple neck 11 Double head bolt steering knuckle arm 12 Upper arm left steering knuckle 13 Left steering knuckle arm 14 Steering limit bolt 15 Dovetail form lockpin king pin 16 Front axle 17 Adjusting spacer 2 1mm 2 8mm 18 Thrust bearing assy 19 Right steering knuckle arm 20 Right steering knuckle ...

Page 62: ...t assy 5 Front brake air chamber assy 6 O ring 7 Front brake cam 8 Bush air chamber bracket 9 O ring 10 Adjusting spacer 11 Front brake adjusting arm assy 12 Washer brake cam 13 Adjusting washer 14 Front brake bottom plate assy 15 Shaft brake shoe 16 Bush 17 Screw 18 Pin 19 Rivet 20 Brake friction plate 21 Front brake shoe 22 Return spring ...

Page 63: ...g the service life and assure the safe run ning of the vehicle If you follow the maintenance schedule to do the maintain your vehicle may obtain the best economic benefit The items of the periodical maintain are as following 1 Add some grease to the grease nipple 2 Avoid important nut loosed 3 Adjust wheel hub bearing pretightening force and toe in 4 Adjust the brake clearance Periodical Maintain ...

Page 64: ...re add the grease measure both left and right of the starting force at cotter pin of steering knuckle journal and the starting force should be 10N Adjustment of front wheel hub pretightening force 1 Apply some 2 lithium grease on the thread of the steering knuckle shaft end and the wearproof spacer 2 Tighten the locking nut by a torque of 120 150N m 3 Turn the wheel hub for 2 3 circles to correct ...

Page 65: ... chamber push rod travel Adjust travel Friction plate overheated or deterioration Replace friction plate Improper connceting condition of the friction plate Correct the joint position of friction plate Water enterred the brake drum Press down the brake pedal during running to exhaust the water Grease on the connecting face of the friction plate or the brake drum Cleanup the grease or replace frict...

Page 66: ...b bearing Kingpin and bush overworn Correct or replace troubled parts Steering knuckle distortion Replace Improper wheel alignment Check and adjust Pulling to one side Improper wheel alignment Check and adjust Front axle bent Correct or replace Brake unsmooth See the relative brake items Front wheel hub bearing nut loosed Tighten accord to the required torque Tire unevenly worn or earlier worn Imp...

Page 67: ...uckle kingpin lithium grease 2 Tie rod ball pin lithium grease 2 Wheel hub bearing lithium grease 2 Adjusting arm lithium grease 2 Cam bracket lithium grease 2 Part Tighten Torque N m Steering draglink arm nut 120 140 Nut of the left and right steering knuckle arm 120 140 Front brake bottom plate bolt 140 170 Air chamber bracket fixed bolt 55 70 Air chamber fixed bolt 55 70 Pin lock nut 55 70 Stee...

Page 68: ...mm Cam shaft end 0 40 0 70mm Clearance difference between two shoes of the same side is 0 1mm Item Maintaining Standard Wear Limit Remark Outside diameter of kingpin 31 9 32mm 31 9mm Clearance between kingpin and steering knuckle bush 0 025 0 077mm 0 20mm Clearance between kingpin and front axle hole 0 01 0 052mm 0 10mm Clearance between steering knuckle and front axle 0 05mm 0 15spacer adjustment...

Page 69: ...tents Structure RA 1 Maintenance RA 3 Assembly and Adjustment RA 4 Trouble Analysis RA 8 Lubricating Parts and Lubricant RA 7 Tightening Torque of Important Bolts and Nuts RA 7 Main Adjusting Data and Maintaining Standard RA 8 ...

Page 70: ... bush axle shaft bolt 2 Axle shaft rear axle 3 Gasket axle shaft 4 Double head bolt small teeth 5 Inner oil seal support ring rear axle 6 Housing assembly rear axle include NO 5 7 Ventilate plug assembly 8 Oil filling plug 9 Oil level indicating plug 10 Oil drain plug assembly ...

Page 71: ...m ring cage ring 11 Bolt 12 Spring washer 13 Rubber plug 14 Dustproof shield 15 Brake bottom plate 16 Set screw 17 Steel lock wire 18 Supporting pin 19 Rivet 20 Brake bush 21 Brake shoe 22 Return spring 23 Return spring pin 24 Spring washer 25 Screw 26 Roller pin shaft 27 Roller 28 Clamp ring 29 Dustproof shield 30 Grease nipple 31 Bush 32 Oil seal 33 Cam shaft 34 Brake friction plate ...

Page 72: ...llow the maintenance schedule to do the maintain your vehicle may obtain the best economic benefit The items of the periodical maintain are as following 1 Add some grease to the grease nipple 2 Avoid important nut loosed 3 Adjust wheel hub bearing pretightening force and brake clearance 4 Add and replace the gear oil for the reductor Periodical Maintain Schedule Item Maintenance Interval Mileage 1...

Page 73: ...bly and front outer bearing inner ring in sequence at the spline end of the gear 4 Measure the pretightening load of the drive gear bearing install the oil seal assembly thrust washer flange fork and washer then tighten the castle nut with a torque 350 500N m and measure the pretightening force at this time the starting force of pulling the flange hole of the bearing seat should be 12 30N 5 If the...

Page 74: ... t turn to make the clearance become zero then turn with the counter clockwise until you hear two sounds of steel ball and the middle part clearance of the brake friction plate is 0 4 0 7mm Gear contact zone Adjusting method 1 Proper contact zone No need to adjust 2 The drive gear the driven gear is too far The drive gear and the driven gear is too far reduce the thickness of the spacer 3 The driv...

Page 75: ...ondition Improper adjustment of the brake air chamber push rod travel Adjust travel Friction plate overheated or deterioration Replace friction plate Improper connceting condition of the friction plate Correct the joint position of friction plate Water enterred the brake drum Press down the brake pedal during running to exhaust the water Grease on the connecting face of the friction plate or the b...

Page 76: ...ighten bolt by the required torque Oil drain screw plug loosed or the gasket is damaged Tighten screw plug or replace gasket Axle housing distorted because of over load Correct or replace axle housing Vent is blocked or damaged Clean or replace vent plug Brake unstably Improper installation of the brake shoe or return spring is broken Tighten fixed pin lock screw or replace return spring Oil on br...

Page 77: ...le nut 70 95 Rear adjusting nut 150 180 Reductor housing and axle housing connecting bolt 140 170 Axle housing rear cover and axle housing connecting bolt 90 120 Adjusting Item Adjusting Data Tooth space 0 2 0 4mm Clearance between rear fiction plate and brake drum 0 4 0 7mm Item Maintaining Standard Wear Limit Remark Feedhole of the rear axle leaf spring worn Φ 27mm Φ 28mm Radial runout of left a...

Page 78: ...Suspension System FA Table of Contents Trouble Analysis FA 1 Structure FA 2 Disassembly FA 4 Check FA 7 Assembly FA 8 ...

Page 79: ...ng leaf damaged Overload Replace the spring leaf Load as required Vehicle rocked severely Damper failed Replace the damper Spring leaf center bolt is broken U bolt and nut loosed Replace center bolt Spring leaf is broken at the center hole U bolt and nut loosed Replace spring leaf ...

Page 80: ...d underplate with set sleeve assy 3 Center bolt 4 Bush 5 Fixed end bracket 6 Spring pin set bolt 7 Spring leaf pin front suspension 8 U bolt 9 U bolt 10 Cover board front suspension 11 Limit block front suspension 12 Lifting eye bracket 13 Front lifting eye 14 Lifting eye oin set ...

Page 81: ...eaf spring pin 4 Limit block assy 5 Sub leaf spring bracket 6 Bracket lifting eye end 7 Lifting eye with bush assy 8 Leaf spring pin 9 Cover board 10 U bolt 11 Sub leaf spring assy 12 Sub leaf spring underplate 13 Rear leaf spring assy 14 Set pin sleeve 15 U bolt underplate ...

Page 82: ...e front damper dismantle the front damper lower end and take off the related parts 3 Loosen the set nut from the upper end of the damper dis mantle the front damper upper end and take off the front damper 4 After loose U bolts and nuts remove the U bolt cover board and limit block 5 Down the front axle by loose the jack and then the leaf soring is in a free condition 6 Remove the spring rear end l...

Page 83: ...fting eye Disassembly of the rear suspencion 1 Wedge the front wheel lift the rear axle and rear part of the frame with a jack and the safety support then take down the rear wheel 2 Unscrew the set nut from the lower end of the damper and take off the related parts 3 Loosen the set nut of the damper pin from the upper end of the damper remove the related parts and take down the damper 4 Loose the ...

Page 84: ...e threaded sleeve off a little then pull or you can use the pin puller with thread 7 Remove the cotter pin used to fix the front pin of the rear leaf spring then take down the front pin of the rear leaf spring down the jack then remove the rear leaf spring finally 8 Take down the cotter pin of the lifting eye pin and make use of an iron rod diameter 15mm went through the special hole used to remov...

Page 85: ... wear condition of the spring leaf if the wear value is over 15 of the standard thickness please replace the spring leaf Standard thickness of the front leaf spring is 9mm wear limit is 7 65mm Standard thickness of the rear leaf spring is 10mm wear limit is 8 5mm Standard thickness of the sub leaf spring is 8mm wear limit is 6 8mm Note If one of the leaf spring is broken you d better replace the w...

Page 86: ...the nut After tightening the clamp bolt rivet the connecting thread of the bolt and nut to lock Assembly of the front suspension 1 Smear a layer of grease on the spring bush and lifting eye bush before assembling 2 Install the lifting eye to its bracket and insert the pin then tighten the locking nut 3 Install the front leaf spring assembly cover board limit block to the front axle and lift the fr...

Page 87: ...on 1 Smear a layer of grease on the spring bush and lifting eye bush and install the lifting eye to its bracket then insert lifting eye pin then the cotter pin and tighten its lock nut Tightening torque 90 110N m Note When inserting the cotter pin make the inclined face contact to the face of lifting eye pin 2 Set the rear spring to the rear axle and lift the rear axle by the jack 3 Align the fixe...

Page 88: ...stall the underplate sub spring and cover board to the upper of the rear spring then install the U bolt 6 Lift the rear end of the vehicle by a jack take down the support under the frame then down the jack 7 Install the U bolt underplate and damper lower bracket 8 Install the U bolts and nuts and tighten Tightening torque 300 350N m 9 Add grease to the leaf spring pin and lifting eye pin 10 Instal...

Page 89: ...tents Technical Parameter BR 1 Tightening Torque BR 1 Trouble Analysis of Wheel Brake BR 2 Structure BR 4 Front Brake BR 6 Rear Brake BR 8 Frame Brake Pipeline BR 9 Cab Brake Pipeline BR 10 Hand Control Valve Control System BR 11 ...

Page 90: ...ghtening Torque Fasten bolt of the front brake air chamber and its bracket 55 70 Fasten bolt and nut of the front air chamber and brake bottom plate 55 70 Fasten bolt of front brake bottom plate and steering knuckle 160 220 Lock nut of front brake anchor pin with conical sleeve 128 167 Fasten bolt of the rear brake air chamber and its bracket 55 70 Fasten bolt and nut of the rear air chamber and b...

Page 91: ...bolt protrude due to the wear of the brake lining The brake lining surface is harden The brake lining surface deteriorated Bad contact of brake shoe and brake lining Uneven wear of brake drum inner surface or incorrect installation Brake shoe supporting pin loosed The wheel hub bearing worn out The brake drum deformed Replace brake lining Replace brake lining Replace brake lining Rivet up the rive...

Page 92: ... friction lining Abnormal air pressure Air pipes leak air Air compressor doesn t work Improper adjustment of the unloader valve or it failed because of impurities Brake valve leaks air Repair Disassemble and repair the air com pressor Adjust or clean Disassemble and repair the brake valve Trouble Cause Repair Wheel seized Air in brake air chamber Improper lubricant of cam shaft or adjust ing arm r...

Page 93: ...ont brake shoe 7 Front brake cam left 8 Bush front bracket 9 O sealing ring 10 Adjusting spacer 11 Front adjusting arm assy 12 Adjusting spacer 13 Adjusting spacer 14 Front brake bottom plate 15 Shoe plate shaft front brake 16 Bush front brake shoe plate shaft 17 Screw fix shoe plate 18 Spring axis pin 19 Rivet 20 Brake friction wafer 21 Brake shoe 22 Return spring ...

Page 94: ...t brake cam 8 Bush rear bracket 9 O sealing ring 10 Adjusting washer 11 Front adjusting arm assy 12 Adjusting washer 13 Adjusting washer 14 Bush front bracket 15 Rear brake bottom plate 16 Supporting washer front brake shoe 17 Nut 18 Sprung axis pin 19 Rivet 20 Brake friction plate 21 Brake shoe 22 Return spring 23 Screw fix shoe plate shaft 24 Bush front brake shoe plate shaft 25 Brake shoe plate...

Page 95: ...There should not be any crack especially at the two end hooks 7 The diaphragm of the brake chamber should be in good condition It should not have any ageing crazing or crack It is not allowed to use the same size diaphragms of different hardness on one truck 8 Check clearance of all fitting surface Assembly 1 Install the assembled brake backing plate assembly on the front axle steering knuckle Tig...

Page 96: ...uld be Near the anchor pins 0 25 0 40mm Near the camshaft 0 40 0 55mm The difference of clearance at the same end of the two shoes 0 1mm When braking linings worn out and the push rod stroke of the chamber exceeds 40mm partial adjustment should be done immediately to reduce the clearance between the linings and the drum Never turn the anchor pins to destroy the good match of linings and drum When ...

Page 97: ...ends of the rear axle housing the tightening torque of the bolt is 130 160N m and then install the pressing dust shield 3 Install the air chamber bracket and fasten then set to the brake cam and assemble the adjusting spacer After that install the brake adjust arm to the brake cam and lock with a clamp ring connecting the air chamber push rod to the brake adjust arm with flat pin 4 The return spri...

Page 98: ...valve assembly technique sets 11 Lock washer with inner tooth 12 Pipe joint 13 Nylon pipe assy four circuit protective valve 14 All metal lock nut 15 Lock washer with inner tooth 16 Brake hose assy 17 Air pipe assy three way tube joint to right brake air chamber 18 Tube joint straight 19 2nd air pipe assy air compressor to unloader valve 20 Nylon pipe assy 21 Brake hose assy 22 Air pipe assy unloa...

Page 99: ...acket 3 Upper bracket 4 pipes bracket 4 Nylon pipe assy brake valve 21 to hose bracket 5 Nylon pipe assy brake valve 22 to hose bracket 6 Nylon pipe assy brake valve 12 to hose bracket 7 Nylon pipe assy brake valve 11 to hose bracket 8 Jacket sleeve 9 Transition joint ...

Page 100: ...ke steel wire assy 6 Clip single tube 7 Clamping piece 8 Upper bracket single tube clip 9 Lower bracket single tube clip 10 Axis pin 11 Rocker and bush assy 12 Axis pin 13 Cotter pin 14 Shackle 15 Axis pin parking brake rocker 16 Return spring 17 Bracket spring 18 Bracket 19 Spherical washer 20 Release pull rod spring clutch 21 Parking brake puller lever assy ...

Page 101: ...Clip and Fastener BF 1 Cab Front Panel BF 2 Door BF 3 Instrument Panel BF 4 Cab Internal Trims and External Trims BF 4 Seat BF 11 Cab Mounting BF 12 Cab and Cargo Body BF 13 Chassis Frame BF 15 Construction of the Heater BF 16 ...

Page 102: ...to soil or damage them Apply seal glue on necessary place when assembling Be careful not let the glue flow out of the parts when applying When replacing the metal parts extarnal plate of the body be sure to take rust prevention measures Clip and Fastener The following codel and pictures and symbols are subiect ot the clip and fastener in the BF section The clip and fastener must be replaced if dam...

Page 103: ... six fixed nuts from the front bumper each three on left and right side 2 Release off the bumper ass y 3 Disassemble the connection device for right and left fog light 4 Disassemble the clip and bolt 5 Disassemble reinforcement seal washer and i 6 nstallation board for the lights ...

Page 104: ...Cab BF 3 Door Front Door When disassembling the front door it is better to disassemble the cover at front side first Afler adjusting the door or door lock check the door lock open and lock condit ion ...

Page 105: ... Internal trims Side ard floor trims Passenger area Caution Wrap the tip of flat bladed screwdriver with a cloth when removing metal clips from garnishes Disassembly of the side inner trims Disassemble the sun visor Disassemble the rearview mirror 1 Instrument frame welding ass y 2 Oil can cap 3 Instrument frame welding ass y 4 Instrument panel upper cover ass y 5 Ashtray assy 6 Block cover Small ...

Page 106: ... seats Disassemble the safely belt Disassemble the door guardrail Disassemble the rear window glass Door trims Disassembly of the door trims Disassemble lock knob Disassemble inside seal Disassemble inside handle escutcheon rear door Disassemble pull handle Pull out regulator handle ...

Page 107: ...guard board of door rear door Roof trims Disassembly of the roof trims Single seater cab Remove part of headlining from corner and gradually peel headlining off Double seater cab Disassemble the screw and roof bow Remove headlining by peeling if off starting with middle portion ...

Page 108: ...Cab BF 7 Cab External Trims ...

Page 109: ...Front lower cover and lower cover board Side external cover board Front and rear windows Cab door seal strips Door and window seal strips Front pedal cover and pedal mat option Front upper finisher Front grille Front corner panel ...

Page 110: ...Cab BF 9 Front and rear window Cab door seal strip ...

Page 111: ...Cab BF 10 Door outside molding Foot step shield and mat ...

Page 112: ...an accident whatever the nature of the accident is the belt assembly must be replaced If any part of the belt has quality problems it must be replaced instead of repairing it If there is any cut looseness or damage on the texture etc replace the assembly Wine oil or other material should not be sprayed into the buckle hole lock so does not the huckle and the knob ...

Page 113: ...ar arm assy 2 Tilting bracket assy 3 Torsion bar 4 Left bracket front mounting 5 Retainer lower assy 1 Left connecting bracket assy rear mounting 2 Upper cushion assy 3 U suppot welding assy 4 Rear mounting lower cushion assy 5 Right connecting bracket assy rear mount ing ...

Page 114: ... from steering transminsion device brake system and clutch operation system The following parts at least should be disassembled in the area of cab 1 Transmission system and steering control system 2 Hand brake operation and brake drag wire 3 Electric system wire harness and tube Cargo body First disassemble the following part Rear combination light system and license lamp ...

Page 115: ...Cab BF 14 Cab body mounting Note Different model has different shape of cargo body ...

Page 116: ...ng cross member 8 Damper cross member 9 Lifting eye end bracket 10 Rear leaf spring cross member 11 Hook bracket 12 Right side member 13 Fixed end bracket 14 Lifting eye end bracket 15 Engine rear mounting cross member 16 Rear leaf spring cross member 17 Fixed end bracket 18 Sub spring bracket 19 Stiffening plate rear bracket of rear spring 20 Stiffening plate rear bracket of front spring 21 Bolt ...

Page 117: ...nel assy 3 Middle air pipe 4 Right air pipe assy 5 Left door defroster hose assy 6 Defroster nozzle assy 7 Right door defroster hose assy 8 Wind inlet channel assy 9 Plastic nut assy 10 Heater assy 11 Air blower assy 12 Heater control mechanism assy 13 Water inlet tube heater ...

Page 118: ...L 5 Battery EL 6 Alternator EL 7 Starting Division EL 9 Electromagnetic Main Power Switch EL 9 Exhaust Brake System EL 10 Hazard Warning System EL 11 Accessories EL 12 Horn EL 13 Fog Lamps EL 15 Instruments EL 16 Instrument Panel EL 17 Speedometer EL 19 Tachometer EL 22 Water Temperature Meter and Fuel Meter EL 24 ...

Page 119: ... Battery A h 90 Light name Bulb specification Bulb type Remark Front headlamp H4 75 70P P43t 38 Fog light H3 70 PK22s Front combination light PY21W BAV15s Turning light R10W BA15s BA15d Front light Side turning light R10 BA15s BA15d Doom light QT24 5SV SV8 5 Inspection light QT24 21 BA15s 19 Rear combination light P21W BA15s BA15d Reverse light PY21W BAU15s Turning light P21 5W BAY15d Brake light ...

Page 120: ... not good Main supply switch failed One position failed Fusible wire and fuse burnt When turn on the one position switch the switch has not good contact Recharge or replace Make earth line steady Make line steady Replace one position switch Replace fusible wire Replace or repair main supply switch Trouble Cause Remedy Engine can not start and starter runs abnormally Fuel cutoff solenoid fuse burnt...

Page 121: ...but left right turning signal light doesn t go on Left turning light right turning light s joint doesn t contact well Check the circuit from turning signal light switch to lamp When turn on the switch the light continues to go on but does not flash Flasher failed contact maintains engage Front rear bulb failed Replace flasher Replace bulb Turning signal light flashes too quickly Flasher failed Red...

Page 122: ...eaks away Wiper arm s tightening bolt loosens Wiper motor assembly failed 1 Internal coil burns out 2 Wiper motor overlade because of current over powering The rectifier is polluted carbon rotary bearing is seized wiper arm connect not well motor wears constant speed gear fails Find out cause and replace fuse Check and repair Replace wiper switch Check and repair Tighten bolt Check and repair wipe...

Page 123: ...e complete truck are connected as follow In the normal conditions the output of alternator reaches ignition switch lighting and instruments by the way of two fusible wires If the alternator fusible wires are burnt the above systems will continue to operate using the battery power But if the engine stops at the time the systems can t start until replace the fusible wires The fusible wire must be re...

Page 124: ...the electrolyte is found insufficient Charging for over half an hour after filling in order to let the filled distilled water fully fix with the former electrolyte Electrolyte level above the top of the battery plate 15 20mm Battery plate Electrolyte Battery Two batteries 6 QW 90DF are in series Type Less maintenance Nominal voltage V 12 Nominal capacity A h 165 ...

Page 125: ...ervicing Use the alternator with built in rectifier and electric regulator Operation principle The alternator produces self excitation field and operates normally when the charging indicator lamp is extinguished Vehicle model EQ1074T G5AD 666 Nominal voltage V 28 Adjusting voltage V 28 0 3 Nominal current A 45 Nominal revolution r min 6000 Starting revolution r min 1150 Output current A 18 20 1 Ba...

Page 126: ...damaged parts Short circuit between the 3 phases and rotor winding and casing Diode damaged Regulator failed Charging current is too small the battery is insuffi cient No charging at low speed Output voltage is over low Exclude the trouble and replace the dam aged parts Diode is partly damaged The rotor winding has 1 phase or 3 phases bad contact Slipping belt The instrument indicator sometimes ch...

Page 127: ... chassis frame As soon as fuse is burnt the electromagnetic main supply switch will automatically cut off the battery nega tive earthed circuit So there will be no electricity in the complete truck Specification Trouble analysis Vehicle model DFA1064DH01 985 Nominal voltage V 24 Nominal power kW 3 7 Pinion teeth 10 Pinion module 2 54 2 1167 Brake torque N m 40 Brake current A 800 Brake voltage V 1...

Page 128: ... exhaust brake switch clutch switch accelerator switch and electromagnetic solenoid are all on But the exhaust brake will be released when either the clutch pedal or the accelerator pedal is depressed Note The exhaust brake indicator lamp comes on which only indicates the exhaust brake switch is ready for operation not indicates the exhaust brake is operative ...

Page 129: ...Electric System EL 11 Hazard Warning System When the hazard warning switch is in the alarm position the left and right turning signal lamps will flash simultaneously ...

Page 130: ...Electric System EL 12 Accessories Wiper motor Power 50 Revolution Low speed 40 High speed 60 6 2 3 ...

Page 131: ...pen contact of the horn relay is connected and make the electric horn work Horn relay Decrease the current flowing through horn button via an iron core with high resistance so as to prevent the horn button from burning out 1 To horn 2 To power supply 3 To horn button ...

Page 132: ...Electric System EL 14 Electric wiring diagram ...

Page 133: ...ause when the front lamps go on the tail lamps license lamp instrument and quartz clock illuminators should be all lighted simultaneously while the foglamp is not included but when the foglamp goes on the front lamps tail lamps license lamp instrument and quartz clock illuminator should be all lighted ...

Page 134: ...Electric System EL 16 Instruments Structure This part consists of air pressure meter fuel meter water temperature meter tachometer and speedometer Name of the indicators and warning lights ...

Page 135: ...ter temperature meter 40 80 100 120 Nominal voltage V 24 1 Panel assembly 2 Speedometer 3 Washer 4 Self tapping screw 5 Warning lamp pattern piece 6 Big case 7 Soft printed circuit board 8 Nylon rivet 9 Speedometer lighting bulb holder 10 Small warning signal lamp bulb holder assembly 11 Big warning signal lamp holder 12 Oil pressure gauge assembly 13 Fuel level gauge 14 Water temperature gauge 15...

Page 136: ...hod The three small meters can be replaced after the transition connecting parts have been removed which should be fit and tightened after the meters are replaced Reassembly and check Reassemble the removed parts in the reverse order of removal and tighten screws when reassembling Check if there is any part assembled wrongly or any scratches damages and so on Then attach the connectors the tachome...

Page 137: ...reset the meter indicator to zero and then release it before using this speedometer The red figure at the far right with the white background indicates readings in units of 0 1km Note Do not press the reset button during the driving period Do not pull or turn the reset button when press it Technical parameter Type Magnetic inductive Speed indicator range km h 0 140 Mileage counting figures km Tota...

Page 138: ... cover 10 Needle shaft 11 Hairspring 12 Needle Working principle Drive of speedometer The flexible shaft driven by transmission main shaft mounted on the back of the transmission is driven by pulling the square connector into the square hole at the outside of the speedometer turning shaft which drives the digital wheel through three sets of worm wheel and worm Indication of odometer When the flexi...

Page 139: ...e Transmission output shaft slipped Tighten the flange fork under the rec ommended torque The magnetic effect of the magnetic steel reduced Replace Needle indica tion error Hairspring deformed or deviate from the original position Move the hairspring to one side to adjust the indication of the needle Magnetic body cracked Replace meter Dimension of tyre is wrong Replace and use the recommended tyr...

Page 140: ...coil assem bly bracket assembly upper and lower bearing and so on Auxiliary part Base housing screws and electrical connectors The needle seized or failed that can not return to zero Grease on the magnet Clean out the grease Hairspring deformed Replace meter Wrong assembling of the needle needle slack ened Tighten There are impurities absorbed on the magnet of the indication board Clean The day di...

Page 141: ...e hairsprings In addition do not break the coil output wire 1 Needle 2 Screw 3 Dial 4 Light guiding glass 5 Printed circuit board 6 Connection wire 7 Bracket 8 Blade connector 9 Base Trouble analysis Trouble Case Repair The instrument doesn t work Circuit broke Sensor damaged Instrument burnt out Check wire connection and connector with socket s contact Replace sensor Replace instrument Needle sha...

Page 142: ...s Water temperature meter Type Moving magnet Indicating range 40 80 100 120 Meter seat connection 3 M3 6g screw Fuel meter Type Moving magnet Indicating range 0 1 2 1 Meter seat connection 3 M3 6g Trouble Cause Method Fuel meter does not work Open circuit of the sensor resistance wire Replace Open circuit of the sensor and meter electric wire Connect Wrong indication of the fuel meter Sensor float...

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DongFeng DFA1063DJ10-301, Service Manual

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