DongFeng DFA1063DJ10 Service Manual
DONGFENG DFA1063DJ10(14)-301/303
SERVICE MANUAL
DONGFENG AUTOMOBILE CO., LTD.
September. 2006
INDEX
General Principles
Clutch
Gearbox
Propeller Shaft
Steering System
Front Axle
Rear Axle
Suspension System
Brake System
Cab
Electric System
General Principles
GL
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
General Principles
General Principles
This manual mainly states maintenance and service methods of DONGFENG DFA1063DJ10(14)-301/303
light commercial truck.
To use vehicles safely and efficiently, you need to read the manual thoroughly and make sure that you are
familiar with the items that mark "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 maintenance of engine, please refer to service documents offered by Dongfeng Cummins Engine
Co., Ltd.
GL-1
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.
Maintenance standard
The matching clearance or standard performance parameter of
components while assembled.
Reparation limit
It means that the component size or component clearance after
repairing must satisfy the 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
fasteners not mentioned, the structures and the sizes of them have been
standardized and they should be fastened with screwing torques
prescribed in the following table.
M6 M8 M10 M12 M14 M16 M18 M20
Ordinary car-
bon steel
High-strength
alloy steel
5~8 16~23 29~42 50~70 80~110 130~170 160~200 260~320
9~12 18~26 34~48 67~95 120~170 165~220 200~250 320~400
GL-2
General Principles
Maintenance Rule
Maintenance Schedule
It's necessary for periodical inspection and maintenance of truck to prolong its service life, improve its power
performance and fuel economy, so periodical inspection and maintenance should be carefully carried out according to the following items. Then it will achieve the max economic and social benefits.
The following schedule is not only for maintenance items of 80,000km, but also for normal maintenance
items after 80,000Km.
△—maintenance mileage at running-in period (1,500~2,500km)
☆—maintenance items at running-in period
★—maintenance items at regular driving period
Note：
Customers should carry out the inspection and maintenance intervals according to the different area
condition. Properly shorten the maintenance intervals can ensure the truck to get the reasonable maintenance and
move reliability. Never prolong the intervals.
Dongfeng Cummins Diesel Engine
Maintenance Item
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 cooling system
Check the damage of fan belt
Remove the deposit in fuel prefilter
Check and clean air filter element
Replace engine lubricant
Replace oil filter
Check and adjust valve clearance
Replace fule filter and oil & water seperator
Replace air filter element
Check the compression pressure in cylinder
Check the injection pressure of injector
Check injection timing
Check the injection volume of injection pump
Check the working conditions of delivery pump
Check the working conditions of thermostat
Check the working conditions of radiator
Clean the cooling system of engine
Check the working conditions of supercharger,
replace while necessary
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
★★★ ★★★★★★★★★
☆★★★ ★★★★★★★★★
☆★★★ ★★★★★★★★★
☆★★★ ★★★★★★★★★
★★★ ★★★★★★★★★
☆★★★ ★★★★★★★★★
☆★★★ ★★★★★★★★★
☆★★★ ★★★★★★★★★
☆★★★ ★★★★★★★★★
☆★ ★ ★ ★ ★ ★
☆★ ★ ★ ★ ★ ★
☆★ ★ ★ ★ ★ ★
☆★★★★
★★★★
★★
★
★
★
★
★
★
★
★
★★
GL-3
Clutch
General Principles
Maintenance Item
Check the working conditions of clutch
Check the free travel of clutch pedal
Check the leakage of the hydraulic pipeline and
clutch pump
Check the air leakage of clutch booster
Check the reserve of braking fluid in oil reservoir
Replace clutch braking fluid
Propeller Shaft
Maintenance Item
Check the looseness of the linking parts of propeller
shaft
Check the looseness of spider bearing
Check the looseness of middle bearing
Check the wearing conditions of spline
Gearbox
Maintenance Item
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 control mechanism
Check the working conditions of the bearings in
gearbox
Disassemble and check gearbox
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★
★
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
☆★ ★ ★ ★
☆★
☆★
★
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★
☆★★
☆★★
★
★
Suspension System
Maintenance Item
Check the leakage of shock absorber and fasten the
bolts of brackets
Clean front and rear leaf spring and shock absorber
Fasten U bolt of leaf spring when fully loaded
Check the damage and looseness of shock absorber
Check the wearing of pin sleeve of rear leaf spring,
replace while necessary
Check if shock absorber is out of service
Disassemble leaf spring, replace spring pin and pin
sleeve
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
☆★★★★★★★ ★ ★ ★★★
★★★★★★★ ★ ★ ★★★
☆★ ★ ★ ★
★★★★
★
★
★
GL-4
Axle and Wheel
General Principles
Maintenance Item
Clean alxes and wheels
Check the oil leakage of final drive
Check the fastening conditions of important
bolts
Check the pressure in tyres
Check the abnormal wearing of wheels
Check lubricant reserves of final drive, clean
vent plug
Clean and adjust hub bearings
Replace the lubricant of final drive
Wheel changing
Check the working conditions of final drive and
the bearings
Disassemble and check final drive and adjust it
Make megnatic examination for axle shaft tube
Steering system
Maintenance Item
Check the oil leakage of steering gear
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 steering knuckle arm
Check and adjust front wheel toe-in
Check front wheel alignment
Check and adjust steering gear
Disassemble and check the connectors of steering
cross rod and tie rod
Make magnetic examinations for steering knuckle
Replace the ball head pins in steering system
Check power steeering oil reserves, add while necessary
Replace power steering transmission oil
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
★★★★★★★★★★★★
☆★★★ ★★★★★★★★★
☆★★★ ★★★★★
☆★★★ ★★★★★★★★★
★★★★★★★★★★★★
★★★★
★★★★
☆★★
★★★★
★
★
★
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
☆★★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
★★★★ ★ ★ ★ ★ ★ ★ ★ ★
☆★ ★ ★ ★
☆★ ★ ★ ★
☆★ ★ ★ ★
☆★ ★ ★ ★
☆★ ★ ★ ★
★
★
★
★
★
☆★★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
★★
Braking System
Maintenance Item
Check the free travel of brake pedal
Check parking brake and its efficiency
Check the air leakage of braking pipeline
Check and adjust the clearance between brake drum and
friction disc
GL-5
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★
☆★★★★★★★★★★★★★
Braking System
General Principles
Maintenance Item
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
Check battery liquid reserves, add while necessry
Check the proportion of battery liquid
Check the looseness of the rivets in chassis frame
Check the efficency of locking device of titing mechanism
Check the looseness of linking parts of cabin
Check and adjust latches of cargo body
Check the looseness and damage of cross and side
members of cargo body and the linking parts
Check the wearing of latches, replace while necessary
△
☆★★★ ★ ★ ★ ★ ★ ★ ★ ★ ★
☆★★★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
☆★★★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
△
☆★★★★
★★
★
Maintenance Mileage Interval( × 1,000km）
4 8 12 16 20 24 28 32 36 40 44 48 80
★★★★
★★
★★
★★
★
Recommended Fuel and Lubricant
The quality of fuel and lubricant can effect the performances, quality and even life of vehicles. Therefore, to
ensure normal operations of vehicles, suitable oil products should be used according to relative prescriptions.
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.
Fuel
Qualified light diesel in accord with GB252—87 Standard should be used. Users can choose specific class of
light diesel according to the specific temperature in his region.
Recommended temperature scope:
Class Recommended Temperature
0# light diesel
10# light diesel
20# light diesel
35# light diesel
50# light diesel
Engine lubricant
above 4 ℃
above -5 ℃
between -5 ℃ ~ -14 ℃
between -14 ℃ ~ -29 ℃
between -29 ℃ ~ -44 ℃
High-quality lubricant meeting following standards must be used for Dongfeng Cummins engines:
Lowest standard： CF-4/SG 15W-40
Recommended Standard：CG-4/SH 15W-40
Ideal standard： CH-4/SJ 15W-40
GL-6
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. Applicable
environment temperatures for different classes are as follow:
Gearbox oil
Recommend to use sulfur-phosphor 85W/90 GL-4 gear lubricant for middle duty vehicle.
Lubricating grease
Recommend 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 (coolant)
Recommend to use long-term antirust & antifreeze liquid. The freeze point of the antifreeze liquid used
should be 8 ℃ lower than the minimum local temperature. Different classes of antifreeze liquid can not be used
together.
Volume Data
Part
Fuel tank 120
Engine lubrication system 9
Engine cooling system 14.5
GL-7
Vo l u m e （L）
Volume Data
General Principles
Part
Gearbox 4.2
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
Vo l u m e （L）
Protective Measures while Repairing
To assure safety in repairing, the following protective measures
should be taken all the way:
1） Before reparation, you should ensure that the wheels can not
turn. The measure to lock wheels is as the sketch map.
2） Ensure that the gearbox is at neutral position.
3） Ensure that the ignition switch is at "off" postion.
4） When 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.
GL-8
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. Part damages
may be revealed during the cleaning, so great attention should be paid while cleaning.
Metal parts
Light oil: in contrast with other solutions, light oil can't penetrate or dissolve mud. Therefore, except for
finished surface, mud should be removed by wire brush or other tools and should be cleaned in this way for two
times.
Alkali solution: if the parts are made of alloy, don't use alkali solutions for the cleaning. Instead, alkali
solutions are very effective for the cleaning of steel and cast iron.
Note:
If alkali solutions are being used, you should make some correctives such as boric acid solution. Once your
eyes or skin touch the alkali solution, you should use the corrective to clean.
Rubber parts
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 components with special gauges or tools. Decide whether a component can continue to
serve according to specified maintenance standards. Damaged components should be repaired or replaced as
required. If one of a pair of components fitted together is worn so much that the fit clearance exceeds the specified
range, replace the pair of components together.
Out of consideration of preventive maintenance, some components should be replaced before them reaching
service limit.
Carefully inspect the surface of components by outlook or red check method. Repair or replace the component if its surface has the following abnormal signs: uneven wear, biased wear, scratch, crack, distortion, malfunction or becoming weak (spring), bended, loose, abnormal noise (bearing), distortion, malfunction or becoming
weak (spring), bended, loose, abnormal noise (bearing), discolored, seized, eroded, deteriorate (friction lining),
etc.
All the rubber pieces, such as O-rings, oil seals and washers cannot be further used after disassembled.
GL-9
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 structure of each part as well as the functional connection between various parts.
To resolve a problem of the vehicle, you must first know the nature of the trouble. To achieve this, you must
get some exact knowledge of the trouble from the customer, including the parts that effect using conditions and
the date of the happening of the trouble.
A trouble may be caused by one or many reasons in most cases. Therefore, to examine and repair requires
the ability of systematic thinking and resolving problems step by step. For example, when the steering wheel turns
unstable, you should first examine the connection mechanism of the pitman arm instead 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. Listed below are some common trouble signs and their reasons. As
for the detailed trouble analysis, please refer to chapter of each assembly.
1. During starting of the engine (neutral position)
Engine can
not start
Listen to the sound of the gear of the
gear of the starter Folo-tru drive
No sound Trouble in starting system
Having sound Engine troubled
2. After engine started
Abnormal sound Engage a gear Sound does not stop Clutch cover troubled
Engine troubled
Exhaust system troubled
Sound stops Clutch driven disc troubled
Transmission troubled
3. During starting of vehicle
Abnormal sound Clutch troubled
Transmission troubled
Propeller shaft troubled
Rear axle troubled
Engine drive belt slipped
GL-10
General Principles
Unstable running of vehicle Engine troubled
Incomplete release of parking brake
Incomplete release of brake
Bumpy running of vehicle Clutch troubled
4. During vehicle running
Poor acceleration Clutch slipped
Incomplete release of brake
Incomplete release of parking brake
Engine fuel system troubled
Overload of propeller shaft
Engine rubber mounting failed
Abnormal noise Continuous noise Transmission troubled (oil insufficient or deteriorate)
Reductor 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 troubled
Uneven wear of tyre or imbalance of tyres
Engine mounting troubled
Cab mounting troubled
Unstable running (straight) Incorrect front wheel alignment
Front axle troubled
Suspension spring troubled
Steering system troubled
incomplete release of brake
Uneven tyre pressure
GL-11
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 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
Brake can't be released completely Brake system troubled
Hub bearing clearance too large
GL-12
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
Clutch
Clutch
Main Parameter
Distributing diameter (mm)
Bolt install hole size
Positioning pin hole size
Angle between positioning hole and installing bolt hole
Friction lining size D×d
Working pressure force 11300±13500
Release bearing stroke (mm) 10~11.5
Pressure plate lift range (mm)
Height of release finger (mm) 56±1.6
Unbalance static of the cover assembly (g.cm)
Unbalance static of the driven disc assembly (g.cm)
Torque (N.m) Mmax=1087
Note:
The DOT4 compound brake fluid is recommended to the clutch.
Unclean or dirty brake fluid is forbidden to use.
Do not splash the brake fluid down to the paint. (It may erode the paint.)
You must make use of the tools to disassemble and assemble the clutch pipeline system.
Make use of the clean brake fluid to clean the master cylinder, booster and the fluid reservoir.
The mining oil such as gasoline, kerosene, etc., it will erode the rubber parts in the hydraulic pressure system.
After clean the clutch pressure plate, dry it with the suction cleaner, not the compression air.
Aperture (mm)
Number of holes 8 (4 pairs)
Distributing diameter (mm)
Aperture (mm)
Number of holes 2
Φ 9.5 (+0.061, +0.025)
Φ 7.9 (+0.061, +0.025)
Φ 379
Φ 10.5 (+0.27)
Φ 384
10°
Φ 325× Φ 200
≥ 1.5
≤ 70
≤ 35
CL-1
Clutch Control Mechanism
Clutch
Clutch Mechanical System
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
CL-2
Clutch Control Pipeline
Clutch
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
booster
5.Hose bracket
6.Front hose assy--clutch
7.Rear oil pipe assy--clutch master pump to
booster
8.Clutch rear oil pipe bracket
9.Rear hose assy--clutch
10.Booster assy
11.Nylon hose assy
12.Oil reservoir assy
Adjustment of Clutch Pedal
1.Adjust the height of the clutch pedal by adjusting the pedal setting bolt. The height of clutch pedal is about
160~170mm.
2.Adjust the free stroke of the clutch pedal.
Release bearing
Check the release bearing for any crack or wear. The release bearing must be smooth and turn without noise.
Replace it if necessary.
Check the release sleeve and release 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.
CL-3
Clutch driven disc and pressure plate
Clutch driven disc
Clutch
1.Rivet--friction disc
2.Rivet--catch plate
3.front damping 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
CL-4
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. Replace if necessary.
Installation
Smear some grease on the connecting surface and the spring.
Over much grease may damage the surface of the driven disc.
Clutch pressure plate
Check and adjust
Check the height and plainness of the diaphragm.
When checking the height of the diaphragm, set a clearance
gauge(T=0.2mm) on the distance bushing.
Height of the diaphragm: 41~43mm (base disc to the top of the diaphragm)
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 damage 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 dirt, make
use of the corundum paper to get rid of them if necessary.
Check the connecting side of the pressure plate and the driven disc
for any distortion or damage, and replace them if necessary.
Adjust the plainness of the diaphragm by tools.
Plainness: <0.7mm
Flywheel check
Check the working face of the flywheel for ablation or color changed,
make use of the corundum paper to get rid of them if necessary.
Check the plainness of the flywheel surface: <0.1mm
CL-5
Clutch
Clutch 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
CL-6
Clutch
When install the clutch pressure plate and driven disc, insert the special 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
hole, locating pin hole or locating exicrcle match the flywheel.The thickness of the driven disc also has to accord the requirements.
During the installation, first insert the locating mandrel into the
spline hole of the driven disc and set it on the flywheel end. Then install
the cover assembly to the flywheel and tighten the 8 installation bolts
equably. When tightening the bolts, do remember to make the locating pin
into the locating hole correctly.
When adjust 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 over loaded during using to avoid skid and
cause wear.
Never make the driven disc in a half engaging situation during using
to avoid too much wear earlier.
3.Maintenance
If the driven disc has been a little bit worn, you must adjust the control mechanism periodically to assure the proper free travel.
When the friction plate is worn too much like the distance between its
surface to the rivet head is not more than 0.5mm, you have to change a
new one.
When maintaining the engine, you must clean up the surrounding
place of the inner support disc and ring of the cover assembly.
If you need to disassemble the pressure plate to do the clean, do
remember to assemble it to its original place to assure its balance.
CL-7
Transmission
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
Transmission
Maintenance Standard
Technical Parameter
Assembly Name DONGFENG 17G1A2-DJ10
Transmission Model A121J
Transmission Type
Control System Double flexible shaft cable, remote control
Center Distance (mm) 121.125
Output Torque (N.m) 1820
Gear Type
Speed Ratio
Capacity of lubricant (L) 5.5
Lubricant type Sulfur-phosphor middle loaded 85W/90 API GL-4 gear oil
1st, reverse gear Straight tooth
2nd~5th gear Skewed tooth
1st gear 4.763
2nd gear 2.808
3rd gear 1.594
4th gear 1.00
5th gear 0.756
Reverse gear 4.99
Mechanical type, 5 forward gears, 1 reverse gear; 2nd~5th gear with
synchrinizer
Maintenance Standard
Item
Trans-
mission
top cover
Trans-
mission
upper
cover
Trans-
mission
body
Synchro-
nizer
Clearance between gear select rocker block and
gear shift lever block slot
Tooth space between control shaft and gear
shift lever spline
Clearance between transmission fork shaft and
transmission fork hole
Clearance between end face of the reverse gear
fork and ring groove
Clearance between end faces of other gears and
ring groove
Axial clearance of output shaft 2nd gear 0.1~0.37 -- 0.4
Axial clearance of output shaft 4th gear 0.1~0.35 -- 0.4
Side play between output shaft and 1st, reverse
gear soline
meshing play of running gear 0.15~0.26 -- 0.5
Max. turning quantity of balking ring end face -- -- 1.0
Max. wearing of balking ring bevel -- -- 0.1 Bevel groove
Clearance between balking ring end face and
cone disc end face
Nominal
Dimension
（mm）
0.1~0.4 -- 0.8
0.05~0.11 -- 0.5
0.140~0.101 -- 0.25
0.5~0.8 -- Not drop
0.2~0.5 -- Not drop
0.055~0.175 -- 0.3
3 -- -- Single side
Sevice
Standard
（mm）
Repair
Limit
（mm）
Wear Limit
（mm）
MT-1
Tightening Torque
Transmission
Item
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 20
Countershaft rear bearing locking nut 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
Tightening Torque （Nm）
Trouble Shooting
Abnormal noise
Check the abnormal noise from transmission to determine if it happens during driving or gear shifting, which is
one of the factor to the trouble shooting. Also, find out this abnormal noise comes from gear or bearing.
Trouble Cause Correction
· Use suitable lubricating oil
· Add it to required level
· Repair or replace the part
· Replace the bearing
· Check shift fork, replace it if its twist
· Replace
· Clean, replace
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 shift fork and gear incorrect
· Synchronizer worn out or damaged
· Some gears broken
Gear engagement is difficult
When gears of transmission are difficult or tend to disengaged, you must consider that is failure of control system
that the transmission inside mehanism is isolated from the gear shift lever to gear shift fork.
When there is failure of transmission engagement, the problem maybe caused by malfunctioning synchronizer
and this kind of problems normally occur at the certain speed, as 2
Trouble Cause Correction
Control system
· Operating level deformed
· Gear select or shift flexible shaft length incorrect
Transmission
Difficulty
in shifting
· Bearing worn out or damaged
· Malfunctioning of synchronizer
· Gear select and shift rocker welding point loosened
· Fork deformed or damaged
· Shift lever come out from groove
· Malfunctioning of gear shift rocker bolt
· Fork stopping screw loosened
nd
speed or 3rd speed.
· Adjust operating lever
· Adjust flexible shaft length
· Replace bearing
· Replace synchronizer
· Weld, repair
· Check, adjust or replace
· Assemble or replace parts
· Replace bolt
· Tighten, lock
MT-2
Transmission
Difficulty
in shifting
Others
· Abnormal disengagement of clutch
· Viscosity of lubricating oil too large
· Adjust clutch
· Use suitable lubricating oil
Gear throw out of mesh in operation
Trouble Cause Correction
Control system
Transmission
gear jump
automatically
Shift disorder
· Incorrect adjustment of control system
· Mobile shift lever moved caused by the vibration of truck
· Gear shift fork deformed or worn out
· Self lock ball or ball groove of gear shift fork
shaft worn out
· Self lock 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
· Inter lock steel ball or inter lock pin worn out
or forgotten assemble
· Check and correct the control hinge
· Check the engine and cab rubber mount
for damage, replace faulty parts
· 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
· Tighten the nut as required
· Disassemble to check or assemble
Oil leak
Trouble Cause Correction
· Drain some lubricating oil
· Replace
· Tighten
· Unplug
· Spread on sealing glue and assemble
Oil leak
· Excessive lubrication oil
· Sealing element worn out or failed
· Fastening part loosened
· Vent plug plugged
· Forget to spread on bolt sealing glue
MT-3
Transmission
Construction
Transmission housing and imput shaft
1.Front bearing--input shaft
2.Bearing cover--input shaft
3.Oil seal--transmission input shaft
4.Gasket spacer--input shaft bearing cover
5.Circlip for shaft
6.Steel snap ring for shaft
7.Rear ball bearing--input shaft
8.Transmission imput shaft
9.Transmission imput shaft and ball bearing assy
10.Front bearing cover--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 shaft joint
21.Gasket spacer--intermediate shaft rear bearing
22.Rear bearing cover--intermediate shaft
23.Gasket spacer--reverse gear checking hole cap
24.Cap--reverse gear checking hole
MT-4
Transmission
Transmission output shaft and gear
1.Conical disc--4th, 5th gear synchronizer
2.Balking ring assy--4th, 5th gear synchronizer
3.Balking ring--4th, 5th gear synchronizer
4.Lockpin--4th, 5th gear synchronizer
5.Locating pin--synchronizer
6.Steel ball
7.Lockpin spring
8.Slide gear sleeve--4th, 5th gear
9.Fixed toothholder lock ring
10.Fixed toothholder thrust ring
11.Fixed toothholder--4th, 5th gear
12.Needle bearing
13.4th gear
14.4th gear shaft sleeve
15.4th gear thrust ring
16.3rd gear
17.3rd gear needle bearing
18.Conical disc--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, reverse gear
32.Reverse gear shaft bush
33.Driven gear--reverse gear
34.Thrust ring--output shaft rear bearing
35.Rear roller bearing--output shaft
36.Driven gear--odometer
37.Steel snap ring for shaft
38.Drive gear--odometer
39.Spacer sleeve--output shaft rear bearing
40.Saucer spring
41.Lock nut--transmission flange
42.Circlip for shaft
43.Spacer
MT-5
Transmission
Transmission intermediate shaft, reverse shaft and gear
1.Front roller bearing--intermediate shaft
2.Circlip for shaft
3.Constant mesh gear--intermediate shaft
4.4th gear spacer sleeve--intermediate shaft
5.4th gear lock ring--intermediate 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 shaft lock shim
22.Sealing ring--everse gear shaft
MT-6
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