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DongFeng DFA1063DJ10-301 Service Manual

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DONGFENG DFA1063DJ10(14)-301/303
SERVICE MANUAL
DONGFENG AUTOMOBILE CO., LTD.
September. 2006

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Summary of Contents for DongFeng 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 Electric System...

  • Page 3: Table Of Contents

    General Principles Table of Conntents General Principles...................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: General Principles

    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 maintenance of engine, please refer to service documents offered by Dongfeng Cummins Engine Co., Ltd. GL-1...

  • Page 5: Operational Instruction

    General Principles Operational Instruction You can neglect the structural differences between the part in the manual and the corresponding one of your vehicle, because the manual is just teaching you principles for your operation. Standard Terms Vehicle direction Vehhicle direction referred in the manual is marked as the right picture.

  • Page 6: Maintenance Rule

    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. Dongfeng Cummins Diesel Engine Maintenance Mileage Interval( × 1,000km） Maintenance Item △...
  • Page 7 General Principles Clutch Maintenance Mileage Interval( × 1,000km） Maintenance Item △ 4 8 12 16 20 24 28 32 36 40 44 48 80 Check the working conditions of clutch ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ Check the free travel of clutch pedal ☆...
  • Page 8 General Principles Axle and Wheel Maintenance Mileage Interval( × 1,000km） Maintenance Item △ 4 8 12 16 20 24 28 32 36 40 44 48 80 Clean alxes and wheels ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ Check the oil leakage of final drive ☆...

  • Page 9: Recommended Fuel And Lubricant

    DongFeng Automobile Co., Ltd. prescribes the most suitable fuel and lubricants for its products. The foll- wing are the fuel and lubricants that should be used in our products.
  • Page 10 General Principles Note: Engine damages for using lubricants below CD15W-40 or CE15W-40 or even lower are not in our warranty scope. Suitable temperature scope: For 15W-40: -10 ℃ ~-15 ℃； For 10W: -5 ℃ ~-20 ℃ ; For 5W-30: below -25 ℃ Lubricant for gears in driving axle Recommend to use sulfur-phosphor API GL-5 gear lubricant for heavy duty vehicle.

  • Page 11: Protective Measures While Repairing

    General Principles Volume Data Part Volume （L） Gearbox Rear axle Add till the oil overflow from the inspection hole Clutch Add to the scale of "MAX" of clutch oil reservoir Power steering gear Add between the upper and lower scale of oil tank Protective Measures while Repairing To assure safety in repairing, the following protective measures should be taken all the way:...

  • Page 12: Cleaning

    General Principles 6） When disassemble or assemble the assemblies that have been taken down, you should ensure that they are on a solid worktable to avoid they would drop or turn over. Cleaning Because the parts may be covered by dirty oil and mud, cleaning is compulsive. Applicable cleaning methods include steam cleaning, pressure cleaning, light oil cleaning, acid or alkali cleaning, neutral medium cleaning, trichlorethylene steam cleaning, Magnus solution cleaning, etc.

  • Page 13: Trouble Analysis

    General Principles Trouble Analysis In a vehicle, a part is made up of many components. Some parts like clutch, transmission and rear axle are interactive functioning. Therefore, in order to find and examine trouble exactly, it is necessary to know the struc- ture of each part as well as the functional connection between various parts.
  • Page 14 General Principles Unstable running of vehicle Engine troubled Incomplete release of parking brake Incomplete release of brake Bumpy running of vehicle Clutch troubled Overload of propeller shaft Engine rubber mounting failed 4. During vehicle running Poor acceleration Clutch slipped Incomplete release of brake Incomplete release of parking brake Engine fuel system troubled Abnormal noise...
  • Page 15 General Principles Abnormal steering operation Heavy steering Steering system troubled Incorrect front wheel alignment Front axle troubled Over low pressure of front wheel Turning wheels not return Steering system troubled Incorrect front wheel alignment Front axle troubled Insufficient steering angle Steering system troubled Front axle troubled Abnormal gear shift...
  • Page 16 Clutch 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: Main Parameter

    Clutch Clutch Main Parameter Distributing diameter (mm) Φ 379 Bolt install hole size Aperture (mm) Φ 10.5 (+0.27) Number of holes 8 (4 pairs) Distributing diameter (mm) Φ 384 Φ 9.5 (+0.061, +0.025) Positioning pin hole size Aperture (mm) Φ 7.9 (+0.061, +0.025) Number of holes Angle between positioning hole and installing bolt hole 10°...

  • Page 18: Clutch Mechanical System

    Clutch Clutch Mechanical System Clutch Control Mechanism 1.Clutch pedal bracket assy 6.Return spring--clutch pedal 2.Lower fixed plate--pedal bracket 7.Bush--pedal assy 3.Clutch pedal welding assy 8.Pin 4.Protective sheath--pedal 9.Clutch master pump assy 5.Clutch pedal shaft CL-2...

  • Page 19: Adjustment Of Clutch Pedal

    Clutch Clutch Control Pipeline 1.Clutch master pump assy 7.Rear oil pipe assy--clutch master pump to booster 2.Front oil pipe assy--clutch master pump to slave pump 8.Clutch rear oil pipe bracket 3.Straight joint 9.Rear hose assy--clutch 4.2nd front oil pipe assy--clutch master pump to 10.Booster assy booster 11.Nylon hose assy...
  • Page 20 Clutch Clutch driven disc and pressure plate Clutch driven disc 1.Rivet--friction disc 11.Disc hub set 2.Rivet--catch plate 12.Spline disc 3.front damping disc 13.Damping spring1 4.Friction disc 14.Damping spring2 5.Damping fin 15.Rear damping disc 6.Driven disc clamping plate 16.Half ring pressure board 7.Driven disc 17.Catch plate 8.Driven disc rivet...
  • Page 21 Clutch Check Check the degree of wear of the driven disc surface. Wear limit: (from friction surface to the rivet head) 0.3mm. Check the spline tooth clearance and the run out tolerance of driven disc. Check the driven disc for ablation, color changed, or contaminated by oil or grease.

  • Page 22: Clutch Cover And Flywheel

    Clutch Clutch Cover and Flywheel 1.Drive spacer 7.Clutch pressure plate 2.Rivet--cover 8.Cover 3.Spacer sleeve 9.Balance rivet 4.Rivet--diaphragm spring 10.Rivet 5.Supporting disc 11.Stop spacer 6.Diaphragm spring 12.Spring washer CL-6...
  • Page 23 Clutch When install the clutch pressure plate and driven disc, insert the spe- cial tool into the clutch driven disc spline (used to align and orient). Screw down the fixing bolt of the clutch cover. Screw down the bolt in an crossed sequence, following two steps. 1.Installation and adjustment Check the type of the clutch to make sure if it is accord to the vehicle model before installation, then find out if the size of installation screw...
  • Page 24 Transmission 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: Maintenance Standard

    Transmission Maintenance Standard Technical Parameter Assembly Name DONGFENG 17G1A2-DJ10 Transmission Model A121J Mechanical type, 5 forward gears, 1 reverse gear; 2nd~5th gear with Transmission Type synchrinizer Control System Double flexible shaft cable, remote control Center Distance (mm) 121.125 Output Torque (N.m)

  • Page 26: Trouble Shooting

    Transmission Tightening Torque Item Tightening Torque （Nm） Clutch housing connecting bolt 137~167 Fasten nut of propeller shaft connecting flange 200~220 Transmission upper cover fixed bolt and nut 33~44 Transmission cover fasten bolt 20~26 Reversing lamp switch and neutral position switch Countershaft rear bearing locking nut 200~300 Reverse gear shaft locking plate bolt...
  • Page 27 Transmission Others Difficulty · Abnormal disengagement of clutch · Adjust clutch in shifting · Viscosity of lubricating oil too large · Use suitable lubricating oil Gear throw out of mesh in operation Trouble Cause Correction Control system · Incorrect adjustment of control system ·...

  • Page 28: Construction

    Transmission Construction Transmission housing and imput shaft 1.Front bearing--input shaft 13.Cover board gasket spacer--power take-off hole 2.Bearing cover--input shaft 14.Square end conical screw plug 3.Oil seal--transmission input shaft 15.Transmission housing 4.Gasket spacer--input shaft bearing cover 16.Rear bearing cover gasket spacer--output shaft 5.Circlip for shaft 17.Rear bearing cover--output shaft 6.Steel snap ring for shaft...
  • Page 29 Transmission Transmission output shaft and gear 1.Conical disc--4th, 5th gear synchronizer 23.Transmission output shaft 2.Balking ring assy--4th, 5th gear synchronizer 24.2nd gear 3.Balking ring--4th, 5th gear synchronizer 25.Needle bearing--2nd gear 4.Lockpin--4th, 5th gear synchronizer 26.Thrust clip--1st gear 5.Locating pin--synchronizer 27.Thimble 6.Steel ball 28.1st gear 7.Lockpin spring...
  • Page 30 Transmission Transmission intermediate shaft, reverse shaft and gear 1.Front roller bearing--intermediate shaft 12.Snap ring 2.Circlip for shaft 13.Nut lockpin 3.Constant mesh gear--intermediate shaft 14.Roung nut 4.4th gear spacer sleeve--intermediate shaft 15.Outside thrust shim--reverse gear 5.4th gear lock ring--intermediate shaft 16.Inside thrust shim--reverse gear 6.4th gear--intermediate shaft 17.Vechile bearing 7.3rd gear--intermediate shaft...
  • Page 31 Transmission Transmission cover 1.Cover 18.Steel ball 2.Straight pin 19.Gasket spacer--cover 3.Bell cap 20.Transmission upper cover 4.Balancing spring--selecting shaft 21.Gasket spacer--upper cover 5.Circlip for shaft 22.Spacer 6.Oil seal--transmission cover 23.Vent plug assy 7.Control shaft and gear shift arm assy 24.Guide block--1st, reverse gear 8.Transmission shift lever 25.Locking gear shift fork shaft spring 9.Steel ball...

  • Page 32: Transmission Disassembly

    Transmission Transmission Disassembly Disassembly procedure Before disassemble assembly, park the truck on the flat ground, shift the transmision in neutral position, switch off the power and wedge up the front and rear wheel to ensure the safety. 1.Tilt the cab. 2.Screw off the drain plug screw, drain off the lubricant oil from transmission when the vehicle is warm.
  • Page 33 Transmission 3.Take off speedometer drive gear and spacer, hold up and sway up and down the front end of mainshaft with hands, tap the rear end of mainshaft from right to left with copper bar to move it backward out of the rear. Take off mainshaft rear bearing snap ring, remove the rear bearing form mainshaft with puller.

  • Page 34: Check

    Transmission 7.Slop the front end of countershaft assembly upward to take out the countershaft assembly from transmission casing. Put a copper rod against the countershaft front bear- ing outer ring and then tap the copper rod to take out the bearing outer ring.
  • Page 35 Transmission Assembly Point Countershaft assembly Press on gear and spacer according to the counter procedure of disassembly, assemble snap ring with sim- ple taper tool. Note: Before press on gear, the gear key groove must align with key on the shaft to avoid damaging. Make sure that the axial clearances of each gear correspond to standard axial clearance.
  • Page 36 Transmission 3.Put the needle bearing and spacer into reverse speed gear inner hole, put the reverse speed gear through the reverse speed gear inspecting hole, insert the reverse speed gear shaft from the transmission casing rear end, seize the lock plate with the bolt to fix it. 4.Put the main shaft into casing, cover the rear bearing from mainshaft rear end, tap the bearing with copper rod to make the bearing get close the shoulder of main-...
  • Page 37 Transmission 7.Put the sealing gasket with sealing glue form input shaft front end to the positing place of bearing cover, cover the bearing cap and tighten it with bolt. Note: Install the clutch release sleeve return spring bracket at the upper left bolt or the bearing cap. 8.Install each sealing gasket with sealing glue onto coun- tershaft front and rear bearing cap, power-take-off cover, reverse speed inspecting hole cover and main-...

  • Page 38: Transmission Control System

    Transmission Transmission Control System General Construction Transmission control mechanism 1.Gear shift konb assy 11.Shift and selector flexible shaft with ball joint assy 2.shift lever assy 12.Flexible shaft clip board 3.Shift rocker shaft 13.Upper bracket, double hose clip 4.Selector rocker shaft 14.Shift, selector flrxible shaft clip board 5.Bushing 15.Flexible shaft bracket assy...

  • Page 39: Check And Adjustment

    Transmission Check and Adjustment Note for installation of flexible shaft 1.Ensure the adjustment for flexible shaft is making in clear environment. If the dirt goes into the tie rod, it will goes into the flexible shaft interior when tie rod move, and cause the damage for flexible shaft core.
  • Page 40 Transmission 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 boll joint and big nut, the dimension of A should meet the requirement.
  • Page 41 Transmission flexible shaft clip on the bracket, then connect the flexible shaft with shift rock arm, the transmission should be in neutral position. 1.Shift flexible shaft clip 3.Selective flexible shaft bracket 2.Selective shift flexible shaft 4.Shift rock arm When assembling, the flexible shaft core must not be twisted. When connecting the flexible shaft with gear- box, the end section of flexible shaft should be about 100mm line, then it can be bent, the bending radius is not less than 200mm.
  • Page 42 Propeller Shaft 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: Technical Parameter

    Propeller Shaft Propeller Shaft Technical Parameter Open type, tubular propeller shaft, two segments. The front Type segment is midship shaft with bearing, the rear is double uni- versal joints with flange inner slide Universal joint type Spider type Center bearing Slide a little along lengthways in the center bearing seat Universal joint max oscillatory angle ±...
  • Page 44 Propeller Shaft Propeller Shaft Structure 1.Flange fork 6.Grease nipple 11.Oil seal spacer 2.Bolt 7.Snap ring for holes 12.Oil seal cover 3.Cross shaft needle bearing assy 8.Slip york assy 13.Propeller shaft assy 4.Dust collar 9.Grease fitting 5.Cross shaft 10.Slip york oil seal PR-2...

  • Page 45: Intermediate Propeller And Center Bearing

    Propeller Shaft Intermediate Propeller and Center Bearing Structure 1.Flange fork 7.Intermediate propeller shaft 12.Bearing seat--center bearing assy 2.Cross shaft needle bearing assy 13.Bearing--center bearing 8.Washer--center bearing seat 3.Dust collar 14.Flange--driving conic gear 9.Center bearing bracket assy 4.Cross shaft 15.Washer--driving conic gear nut 10.Upper cover board--center 5.Grease elbow 16.Hex slotted flat nut...
  • Page 46 Propeller Shaft Measure point of the propeller shaft (mm): A=155 B=165 C=185 3.If the radial runout is above the limit value, remove the connecting flange of one end of the rear axle, and turn it for 180° then install the propeller shaft. 4.Check the radial runout again, if it still beyond the limit value, replace the propeller shaft.
  • Page 47 Propeller Shaft Check Check teh radial runout of the propeller shaft, and if it is beyond the limit 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.
  • Page 48 Propeller Shaft 3.Knock the flange fork with a hammer, and don't dam- age the holes of the spider shaft and flange fork when disassembling the spider shaft. 4.Disassemble the spider shaft bearing of the other end in the same way. Make marks on the dismantled parts, and you may not change their original position when reassembling.
  • Page 49 Propeller Shaft 3.Eliminate the clearance between bearing and snap ring by knocking flange fork. 4.Check the flexibility and axial freedom of the spider 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.
  • Page 50 Propeller Shaft 5.Apply some grease on the lip cavity of the oil seal and then press it into the oil seal seat. 6.Assemble the flange disc and drive gear nut. 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.
  • Page 51 Steering System 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: Check

    Steering System Steering System Note: Before disassembly, carefully clean the surface of the parts. Please do the disassembly in a cleaning invironment to avoid dust or any other filth enter the parts. Put the removed parts in order and it may be convenient to reassem- ble.

  • Page 53: Steering Wheel And Steering Column

    Steering System Steering Wheel and Steering Column 1.Steering wheel assy 12.Return spring 2.Annular ball bearing with doubled sided sealing 13.Distance limit spacer sleeve ring 14.Steering shaft 3.Steering column welding assy 15.Steering universal joint fork 4.Adjusting screw 16.Spider 5.Steering column bracket welding assy 17.Spider needle bearing assy 6.Guiding fin 18.Steering universal joint fork with spline shaft...
  • Page 54 Steering System Steering column When assembling the steering column, tighten the bolt and clip of the lower supporter by hand first. then tighten the steering column under the condition that the steering column is out of force. When assemble the steering cross shaft, you must check if the locking bolt and the sunk part is aligned.
  • Page 55 Steering System Turning lock Remove the fixed bolt of the clip. Tighten the fixed bolt. Note: Take a look if the installing position of the steering lock is correct. Adjusting mechanism After assembling the steering shaft adjusting mechanism, check its moving condition.

  • Page 56: Power Steering Hydraulic Pressure System

    Steering System Power Steering Hydraulic Pressure System 1.Power steering gear assembly 7.Clip 13.Hose 2.Elbow assembly, inlet oil 8.Oil pump 14.Hose--steering gear to oil reservoir 3.Upper bracket 9.Bolt--joint of the oil pump 15.Oil reservoir assembly, steering 4.Elbow assembly, outlet oil, 10.Joint--inlet oil tubing 5.Bracket 11.Jacket 6.Clip...

  • Page 57: Steering Gear

    Steering System Steering Gear Basic parameter Basic parameter M11-3411010 Appropriate maximum load of front axle (kg) 3500 Max. output torque (N.m) 2150 Max. oil pressure (MPa) Recommended oil pump flow (L/min) Drive ratio 18：1 Number of total turns 4.78 Pitman arm shaft turning angle ±...

  • Page 58: Trouble Analysis

    Steering System Trouble Analysis Trouble Cause Method 1.Oil level in steering gear is not suffi- Add oil to the upper mark cient 2..The connecting part between the oil outlet and the engine, and between the oil Tighten oil pipe fitting or replace the seal- inlet of the steering oil pump and the ing part engine, and between the oil pump and the...
  • Page 59 Steering System 1.Too much flow of the oil pump Replace the oil pump Steering gear overheat 2.The bending radius of the oil pipe is (its temperature is over too small or the inner part is blocked and Replace the oil pump cause oil flowing difficult and heated 65°C of the environ- ment temperature)
  • Page 60 Front Axle Table of Contents Construction....................FA-1 Disassembly 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 .......

  • Page 61: Construction

    Front Axle Front Axle Construction Front axle, steering knuckle 1.Upper cover--steering knuckle 11.Double head bolt--steering knuckle arm 2.Gasket--steering knuckle upper cover 12.Upper arm--left steering knuckle 3.King pin--steering knuckle 13.Left steering knuckle arm 4.Upper bush 14.Steering limit bolt 5.Left steering knuckle 15.Dovetail form lockpin--king pin 6.Lower bush 16.Front axle...

  • Page 62: Disassembly Of The Front Brake

    Front Axle Disassembly of the Front Brake 1.Front dustproof shield 8.Bush--air chamber bracket 16.Bush 2.Rubber plug 9.O-ring 17.Screw 3.Column pin--air chamber push- 10.Adjusting spacer 18.Pin 11.Front brake adjusting arm assy 19.Rivet 4.Front brake bracket assy 12.Washer--brake cam 20.Brake friction plate 5.Front brake air chamber assy 13.Adjusting washer 21.Front brake shoe...

  • Page 63: Maintenance

    Front Axle Maintenance Before using new axle, apply enough 2# lithium grease into every grease fitting. First maintain To assure the safe running of your vehicle and obtain a long service life, you have to do the first maintain after the first 1,500~2,500kmafter leaving factory. Please note the following items: 1.Dismantle and check the wheel hub for any abnormal wear (please go to the Assembly and Adjustment to see the reference) 2.Check the fastening piece.

  • Page 64: Assembly And Adjustment

    Front Axle Assembly and Adjustment Disassemble and asseble of the assembly Front wheel hub brake drum assembly 1.Fixed the front axle and remove the wheel hub end cover; 2.Take off the cotter pin, adjusting nut and spacer; 3.Turn the wheel hub brake drum a little and pull it, gently knock at the brake drum at the same time to loose the inner ring of the outer bearing, then take down the wheel hub brake drum, but you need to pay attention that the assembly is so heavy that may be fallen down or hurt someone, and the inner ring of the outer bearing need to care at the same time, don't fall it.

  • Page 65: Trouble Analysis

    Front Axle Adjustment of the brake clearance Turn the worm shaft and shoe shaft of the brake adjusting arm, made the surface of the brake shoe totally connected with the inner face of the brake drum, then loose 3~4 circles of the worm shaft, and adjust the clearance between brake drum inner face and brake shoe: Shoe shaft end: 0.25~0.45mm;...
  • Page 66 Front Axle Improper adjustment of the wheel (too big caster) Check and adjust alignment Too big clearance between kingpin and Check and adjust the clearance Steering wheel heavily bush manipulated Thrust bearing installed on the contrary Correct the installation Front axle lacks of lubricating Add some grease Ball connecting overtighten or too loose Check and lubricate ball head pin...

  • Page 67: Appendix 1 Lubricanting Parts And Lubricant

    Front Axle Appendix 1 Lubricating Parts and Lubricant Lubricating parts Maintenance Interval Mileage ( × 1000km) Item First maintain 12 16 20 24 28 32 36 40 44 48 Steering knuckle kingpin ● ● ● ● ● ● ● ● ● ● ● ● ● Tie rod ball pin ●...

  • Page 68: Appendix 3 Main Adjusting Data And Maintaining Standard

    Front Axle Appendix 3 Main Adjusting Data and Maintaining Standard Main adjusting data Adjusting Item Adjusting Data Toe-in 0~4mm Turning angle of the inside wheel 40° Clearance between front axle fist surface and ≤ 0.1mm the steering knuckle Shoe shaft end 0.25~0.45mm Cam shaft end 0.40~0.70mm Clearance between front fiction plate and brake Clearance difference between two shoes of the same side is...
  • Page 69 Rear Axle Table of Contents 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: Structure

    Rear Axle Rear Axle Structure Rear axle housing and half axle 1.Conical bush--axle shaft bolt 6.Housing assembly--rear axle (include NO.5) 2.Axle shaft--rear axle 7.Ventilate plug assembly 3.Gasket-axle shaft 8.Oil filling plug 4.Double head bolt (small teeth) 9.Oil level indicating plug 5.Inner oil seal support ring--rear axle 10.Oil drain plug assembly RA-1...
  • Page 71 Rear Axle Disassembly of the brake 1.Cotter pin 13.Rubber plug 25.Screw 2. Brake adjusting arm 14.Dustproof shield 26.Roller pin shaft 3.Cotter pin 15.Brake bottom plate 27.Roller 4.Plain washer 16.Set screw 28.Clamp ring 5.U-fork 17.Steel lock wire 29.Dustproof shield 6.Flat pin 18.Supporting pin 30.Grease nipple 7.Locking nut...

  • Page 72: Maintenance

    Rear Axle Maintenance Before using new axle, apply enough 2# lithium grease into every grease fitting. First maintain To assure the safe running of your vehicle and obtain a long service life, you have to do the first maintain after the first 1,500~2,500kmafter leaving factory. Please note the following items: 1.Add or replace the gear oil for the reductor;...

  • Page 73: Assembly And Adjustment

    Rear Axle Assembly and Adjustment Disassemble and asseble of the assembly Rear wheel hub brake drum assembly 1.Fixed the rear axle and remove the half axle bolt by a spanner; 2.Pull out the half axle gently and when the spline passing the oil seal, turn the half axle slowly to avoid damage the half axle oil seal;...
  • Page 74 Rear Axle 6.Paint two or three engaged teeth of driven gear red to chaeck the contact zone, if the contact area is improper, increase or reduce the thickness of the adjusting spacer until it is proper; Sketch map of the contact zone is as follows: Gear contact zone Adjusting method Proper contact zone...

  • Page 75: Trouble Analysis

    Rear Axle Adjustment of the rear wheel bearing pretightening force 1.Remove the stop spacer first; 2.Tighten the adjusting nut by a special spanner with a torque of 150~180N.m; 3.Turn the wheel hub 2~3 circles, and make the bearing aligned correctly; 4.Fasten the adjusting nut with a tightening torque of 150~180N.m;...

  • Page 76: Lubricating Parts And Lubricant

    Rear Axle Improper gear space of the differential Replace spacer or gear Too big clearance between drive gear and Replace spacer or gear driven gear Abnormal noise while Drive gear bearing pretightening force too Adjust pretightening force driving small Half axle gear, planet gear, and cross shaft Correct or replace troubled parts worn or damaged Oil level too low...

  • Page 77: Tightening Torque Of Important Bolts And Nuts

    Rear Axle Tightening Torque of Important Bolts and Nuts Part Tighten Torque (N.m) 130 ~ 150 Oil drain screw plug 350 ~ 500 Big nut of the drive gear 156 ~ 206 Rear brake bottom plate bolt 55 ~ 70 Air chamber bracket fixed bolt 50 ~ 75 Air chamber fixed bolt...
  • Page 78 Suspension System Table of Contents Trouble Analysis..................... FA-1 Structure......................FA-2 Disassembly....................FA-4 Check ......................FA-7 Assembly ......................FA-8...

  • Page 79: Trouble Analysis

    Suspension Suspension Trouble Analysis Trouble Cause Repair Spring leaf damaged Replace the spring leaf Bumpy ride Overload 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 U-bolt and nut loosed Replace spring leaf...

  • Page 80: Structure

    Suspension Structure Front leaf spring 1.Front spring leaf assy 8.U-bolt 2.Inclined underplate with set sleeve assy 9.U-bolt 3.Center bolt 10.Cover board--front suspension 4.Bush 11.Limit block--front suspension 5.Fixed end bracket 12.Lifting eye bracket 6.Spring pin set bolt 13.Front lifting eye 7.Spring leaf pin--front suspension 14.Lifting eye oin set SP-2...
  • Page 81 Suspension Rear leaf spring 1.Fixed end bracket 9.Cover board 2.Wedge lock pin 10.U-bolt 3.Leaf spring pin 11.Sub-leaf spring assy 4.Limit block assy 12.Sub-leaf spring underplate 5.Sub-leaf spring bracket 13.Rear leaf spring assy 6.Bracket--lifting eye end 14.Set pin sleeve 7.Lifting eye with bush assy 15.U-bolt underplate 8.Leaf spring pin SP-3...

  • Page 82: Disassembly

    Suspension Disassembly Clean the suspension system before disassembling. Set the truck in brake state, and block up the front and rear wheel with wooden stand. Dismounting of front suspension 1.Wedge the rear wheel, lift the front axle and front part of the frame with a jack and the safety support, then take down the front wheel;...
  • Page 83 Suspension 7.Remove the fixed bolt of the leaf spring front enf spring pin, then take down the leaf spring pin and let down the jack and take out the leaf spring; 8.Loose the lifting eye locking nut, and take down the lift- ing eye pin and you can remove the lifting eye.
  • Page 84 Suspension 5.Slowly down the jack to fall the rear axle to the ground, and remove the sub leaf spring assembly and sub-leaf spring underplate; 6.Disassemble the the rear end of the the leaf spring. Remove the fasten bolt of the leaf spring pin and pull the spring pin out then you can disassemble the rear end of the leaf spring rear end;...

  • Page 85: Check

    Suspension Check 1.Measure the outer diameter of the spring pin and lifting eye pin Front suspension 17.5mm Wear limit Rear suspension 29.5mm 2.Inner diameter of the spring bush and lifting eye bush Front suspension 19mm Wear limit Rear suspension 31mm 3.Clearance between spring pin, lifting pin and bush: Spring pin and bush: Repair standard...

  • Page 86: Assembly

    Suspension Assembly Assembly of the sub-assembly Assemble the leaf spring by center bolt accord the sequence of the spring leaf; Note: Smear some black lead lime grease on the relative friction surface of the spring leaf. Clamp the leaf spring by a C-shape clip, and tighten the center bolt and nut; Take down the C-shape clip from the leaf spring;...
  • Page 87 Suspension 7.Assemble the U-bolt; 8.Lift the front axle by the jack, and then take down the support of the frame then own the jack; 9.Tighten the U-bolts and nuts; Tightening torque 200~250N·m 10.Install the damper to the bracket, then the plain washer, spring washer and nut, then tighten them;...
  • Page 88 Suspension 4.Install the rear end of the spring, align the lifting eye hole to t spring eye, insert the spring pin, then install the lock nut; Tightening torque 32~42N·m Note:When inserting the cotter pin, make the inclined face contact to the face of lifting eye pin. 5.Install the underplate, sub-spring and cover board to the upper of the rear spring, then install the U-bolt;...
  • Page 89 Brake System Table of Contents 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- Hand Control Valve Control System............BR-11...

  • Page 90: Technical Parameter

    Brake System Brake System Technical Parameter Structure type Air-pressure, with shoe, drum type Brake type S type cam roller type Front Pressing bottom plate Brake bottom plate Rear Foundry bottom plate Front Φ 310 × 120mm Brake specification Rear Φ 310 × 150mm Front Rectangle cam Brake cam type...

  • Page 91: Trouble Analysis Of Wheel Brake

    Brake System Trouble Analysis of Wheel Brake The trouble of brake system including insufficient braking effectiveness, brake being seized, or only one brake shoe expanded, and having abnormal sounding. The worn-out brake shoe lining and the overlarge clearance between the lining and brake drum cause the insufficient braking effectiveness. If you cannot find any causes in the whole brake system, you should consider the brake's condition.
  • Page 92 Brake System Insufficient brake Trouble Cause Repair Normal air pressure Brake valve travel is too short Check and replace the brake valve if necessary Cam shaft doesn't run (bush lacks Check and replace cam shaft if nec- lubricant) essary Improper push rod travel of the brake Adjust the travel air chamber Bad contact of relay valve...

  • Page 93: Structure

    Brake System Structure Front wheel brake 1.Rear dust cap 12.Adjusting spacer 2.Rubber plug 13.Adjusting spacer 3.Axis pin 14.Front brake bottom plate 4.Left bracket--front brake chamber 15.Shoe plate shaft--front brake 5.Front brake chamber 16.Bush--front brake shoe plate shaft 6.Supporting washer--front brake shoe 17.Screw--fix shoe plate 7.Front brake cam, left 18.Spring--axis pin...
  • Page 94 Brake System Rear wheel brake 1.Front dust boot 13.Adjusting washer 2.Rubber plug 14.Bush--front bracket 3.Axis pin 15.Rear brake bottom plate 4.Front brake air chamber bracket (left) 16.Supporting washer--front brake shoe 5.Front left brake chamber assy 17.Nut 6.Spring air chamber bracket spacer 18.Sprung axis pin (thickness=0.05) 19.Rivet...

  • Page 95: Front Brake

    Brake System Front Brake Disassembly Remove the brake drum and wheel hub assembly, take down the return spring, brake shoe, brake cam, air chamber bracket and brake bottom plate in sequence. Check 1.Make sure whether the brake drum is damaged or distorted, replace in necessary. 2.When the brake drum is worn out and becomes out of round, it is allowed to bore, but the accumulative machin- ing quantity should not exceed 4mm for the diameter direction.
  • Page 96 Brake System Adjust After the brake linings have been replaced, the brake bottom plates have been dismounted, causing the positions of the anchor pins and the camshaft changed, the normal contact of the brake linings and the brake drum is destroyed; adjust the brake entirely as follows: 1.Take off the cover of the inspection hole on the drum.

  • Page 97: Rear Brake

    Brake System Rear Brake Disassembly After remove the rear axle half axle, take down the brake drum and wheel hub assembly, then dismount rear brake adjust arm, brake cam, air chamber bracket, brake shoe with bottom plate assembly, and dust shield in sequence.

  • Page 98: Frame Brake Pipeline

    Brake System Frame Brake Pipeline 1.Pipe joint 13.Nylon pipe assy--four circuit protective valve 2.Lock washer with inner tooth 14.All metal lock nut 3.Quick release valve set 15.Lock washer with inner tooth 4.Spring washer 16.Brake hose assy 5.Nylon pipe assy 17.Air pipe assy--three way tube joint to right brake air chamber 6.Nylon pipe assy 18.Tube joint--straight...

  • Page 99: Cab Brake Pipeline

    Brake System Cab Brake Pipeline 1.Brake Valve Assy 6.Nylon pipe assy--brake valve 12 to hose bracket 2.Hose Bracket 7.Nylon pipe assy--brake valve 11 to hose 3.Upper bracket--4 pipes bracket bracket 4.Nylon pipe assy--brake valve 21 to hose 8.Jacket sleeve bracket 9.Transition joint 5.Nylon pipe assy--brake valve 22 to hose bracket...
  • Page 100 Brake System Parking Brake Control Mechanism 1.Parking brake control device assy 12.Axis pin 2.Adjusting nut seat--wiredrawing 13.Cotter pin 3.Spring washer 14.Shackle 4.Bracket 15.Axis pin--parking brake rocker 5.Parking brake steel wire assy 16.Return spring 6.Clip--single tube 17.Bracket--spring 7.Clamping piece 18.Bracket 8.Upper bracket--single tube clip 19.Spherical washer 9.Lower bracket--single tube clip 20.Release pull rod spring--clutch...
  • Page 101 Table of Contents 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....................

  • Page 102: Clip And Fastener

    Precautions When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent scratches. Disassemble or assemble the handle device, molding parts, instrument, inner trims and so on carefully not to soil or damage them. Apply seal glue on necessary place when assembling.

  • Page 103: Cab Front Panel

    Cab Front Panel Disassembling the front bumper ass'y: 1.Release off the 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.

  • Page 104: Door

    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 BF-3...

  • Page 105: Instrument Panel

    Instrument Panel Caution: Before disassembling the instrument panel, switch off the power-supply. Be careful not to scratch pad and other parts. These parts are made of plactic. Excessive force will damage them. The structune of the instrument panel in shown as below: •...
  • Page 106 ③ Disassemble the roof lamp ass'y. ④ Disassemble the handrail. ⑤ Disassemble the seats. ⑥ Disassemble the safely belt. ⑦ Disassemble the door guardrail. ⑧ Disassemble the rear window glass. Door trims Disassembly of the door trims: ① Disassemble lock knob. ②...
  • Page 107 ⑥ Disassemble inner guard board of door (front door). ⑦ Disassemble inner guard board of door (rear door) Roof trims Disassembly of the roof trims Single seater cab ① Remove part of headlining from corner and gradually peel headlining off. Double seater cab ①...
  • Page 108 Cab External Trims BF-7...
  • Page 109 ① Front upper cover ② Front lower cover and lower cover board ③ Side external cover board ④ Front and rear windows ⑤ Cab door seal strips ⑥ Door and window seal strips ⑦ Front pedal cover and pedal mat (option). Front upper finisher, Front grille, Front corner panel BF-8...
  • Page 110 Front and rear window Cab door seal strip BF-9...
  • Page 111 Door outside molding Foot step shield and mat BF-10...

  • Page 112: Seat

    Seat When assemble or disassemble the seat, it should be maintarined clean and well. Front seat Cab Safety Belt Notes: If the vehicle in severely dashed in an accident, whatever the nature of the accident is, the belt assembly must be replaced.

  • Page 113: Cab Mounting

    Cab Mounting Cab front mounting 1.Torsion bar arm assy 4.Left bracket--front mounting 2.Tilting bracket assy 5.Retainer lower assy 3.Torsion bar Cab rear mounting 1.Left connecting bracket assy--rear mounting 4.Rear mounting lower cushion assy 2.Upper cushion assy 5.Right connecting bracket assy--rear mount- 3.U-suppot welding assy BF-12...

  • Page 114: Cab And Cargo Body

    Cab and Cargo Body The following parts at least should be disassembled in the area of cab engine: Main electric system and wire harness. Sparate the engine part 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.
  • Page 115 Cab body mounting Note: Different model has different shape of cargo body. BF-14...

  • Page 116: Chassis Frame

    Chassis Frame Chassis Frame Chassis Frame 1.Front cross member assy 9.Lifting eye end bracket 18.Sub-spring bracket 2.2nd cross member 10.Rear leaf spring cross member 19.Stiffening plate--rear bracket of rear spring 3.Right bracket of rear mounting 11.Hook bracket 20.Stiffening plate--rear bracket of 4.Left side member 12.Right side member front spring...

  • Page 117: Construction Of The Heater

    Chassis Frame Construction of the Heater 1.Left air pipe 8.Wind inlet channel assy 2.Wind channel assy 9.Plastic nut assy 3.Middle air pipe 10.Heater assy 4.Right air pipe assy 11.Air blower assy 5.Left door defroster hose assy 12.Heater control mechanism assy 6.Defroster nozzle assy 13.Water inlet tube--heater 7.Right door defroster hose assy...
  • Page 118 Electric System Table of Contents Specification ....................EL-1 Bulb Type ....................... EL-1 Trouble Analysis..................... EL-2 General Instruction ..................EL-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 ....................

  • Page 119: Specification

    Electric System Electric System Specification Vehicle Model DFA1064DH01-985 Wire system 24V, Single lead type, negative earth Nominal Voltage (V) Starter Nominal Power (kW) Specified voltage (V) Alternator Specified current (A) Battery (A · h) Bulb Type Light name Bulb specification Bulb type Remark Front headlamp...

  • Page 120: Trouble Analysis

    Electric System Trouble Analysis The trouble in the electric system is divided into line trouble, which caused by wire crack or circuit short, and parts trouble, which caused by parts wear or fire. On the other hand, according to the service and maintenance, the system that approaches the final life car easily has trouble.
  • Page 121 Electric System Front headlamp Trouble Cause Remedy Fuse burnt Check cause and replace The headlamp Circuit breaks Check and repair doesn't light Earth line hasn't good contact Get off rust and restring then the joint when turn on Lamp wire burnt Replace bulb the switch Lamp switch has trouble...
  • Page 122 Electric System Fog light doesn't go on Trouble Cause Remedy Fuse burnt Replace Fog light doesn't Earth line contacts not well Tighten go on Bulb burns out Replace Fog light switch damages Replace Position light doesn't go on Trouble Cause Remedy Position light doesn't go no...

  • Page 123: General Instruction

    Electric System General Instruction Constitution Power supply division: Alternator, battery Starting system Power supply warning system Instrument indicator system Lighting system Others: Wiper, horn, cigar lighter, radio cassette player Features Using integrated alternator Using electromagnetic main power switch Two fusible wires at starter 22-way fuse box The complete truck wiring The wires of 22-way fuse box of the complete truck are connected as follow...

  • Page 124: Battery

    Electric System Battery Specifications Battery Two batteries 6-QW-90DF are in series Type Less maintenance Nominal voltage (V) Nominal capacity (A · h) Check 1.Electrolyte density when fully charged: 1.26~1.285g/ cm³ ① Density meter ② Floater 2.Fill distilled water in time if the electrolyte is found insufficient.

  • Page 125: Alternator

    Electric System Alternator Alternator operation principle diagram 1.Battery 3.Charging indicator 2.Electric using equipment 4.Regulator Specification Vehicle model EQ1074T/G5AD-666 Nominal voltage (V) Adjusting voltage (V) 28 ± 0.3 Nominal current (A) 6000 Nominal revolution （r/min） Output current (A) 18-20 Starting revolution （r/min） ＜...
  • Page 126 Electric System Trouble analysis Trouble Cause Method Short circuit or too large contact resistance Charging indicator does not Short circuit between the 3 phases and rotor winding and Check the circuit and extinguish and the truck casing repair or replace the starts difficultly during damaged parts Diode damaged...

  • Page 127: Starting Division

    Electric System Starting Division Starter Vehicle model DFA1064DH01-985 Nominal voltage (V) Nominal power (kW) Pinion teeth Pinion module 2.54/2.1167 Brake torque (N · m) Brake current (A) Brake voltage (V) Starting relay Operating voltage (V) 18~32 Operating current (A) Pull-in voltage (V) 9~17 Drop-off voltage (V) Assistant start button...

  • Page 128: Exhaust Brake System

    Electric System Exhaust Brake System The exhaust brake is operative when the foot is removed from both the clutch pedal and the accelerator pedal; and the 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.

  • Page 129: Hazard Warning System

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

  • Page 130: Accessories

    Electric System Accessories Wiper motor Power －2 Revolution Low speed ＋3 High speed 60 ± 6 EL-12...

  • Page 131: Horn

    Electric System Horn Horn Press the horn button, the normal-open 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.
  • Page 132 Electric System Electric wiring diagram EL-14...

  • Page 133: Fog Lamps

    Electric System Fog Lamps Double rocker switch in parallel is used as a fog switch. That is because 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: Instruments

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

  • Page 135: Instrument Panel

    Electric System Instrument Panel Technical parameter and function Technical parameter Speedometer (km/h) 0~140 Tachometer (r/min) 0~5000 Fuel meter 0-1/2-1 40-80-100-120 Water temperature meter ( ℃ ) Nominal voltage (V) Constitution and function The instrument panel assembly is consisted by speedometer, tachometer, water temperature meter, fuel meter, warning system (14 warning indicator), and matched with the sensor and warner.
  • Page 136 Electric System Disassembly Pull out connectors and the flexible shaft, and then detach wires connected with the electronic tachometer before removing the instrument panel assembly. 1.Remove the speedometer after detaching 3 tapping screw. 2.Pull out bulb when turning the bulb holder counter clockwise to make it aligned with the notch. 3.The voltage drop resistors of small meters are also tightened by tapping screws so that they can be removed.

  • Page 137: Speedometer

    Electric System Speedometer Dial description The speedometer needle indicates the vehicle speed in kilometers per hour. The odometer indicates the accu- mulated driving distance in kilometers. The trip odometer indicates the distance driven per day or driving distance between specified regions. Firmly press the reset knob to reset the meter indicator to zero and then release it before using this speedometer.
  • Page 138 Electric System Structure The speedometer is used to indicate the vehicle driving speed and the accumulated driving distance. It comprises a speed and a mileage unit which records vehicle driving mileage. These two units are inte- grated into one body and driven by the flexible shaft which is connected with transmission output shaft.
  • Page 139 Electric System Trouble analysis Trouble Cause Method Both the speed Flexible shaft core broken Replace division and the Odometer rotating shaft seized Replace the odometer distance count- ing division of the speedometer Square connector nut slackened Tighten again do not work Only the speed Needle deformed and seized with dial or glass Correct...

  • Page 140: Tachometer

    Electric System Trouble Cause Method Grease on the magnet Clean out the grease Hairspring deformed Replace meter The needle seized Wrong assembling of the needle (needle slack- or failed that can Tighten ened) not return to zero There are impurities absorbed on the magnet of the Clean indication board.
  • Page 141 Electric System Instrument assembly and disassembly Before disassembling the instrument, pull out needle 1, and then loosen two screws 2. When disassembling the printed-circuit board; pull it out directly after welding off two wires 9(the printed board and blade connector are directly connected together through a spring blade socket on the board).

  • Page 142: Water Temperature Meter And Fuel Meter

    Electric System Water Temperature Meter and Fuel Meter Dial description Water temperature meter The water temperature meter is used to indicate the temperature of the engine coolant. The temperature of the coolant will change because of the temperature of the atmosphere and vehicle running condition. If the indication of the meter is over its normal range, stop the vehicle as soon as possible.

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