Dongfeng DFA1101GZ5AD6J-907. Manual - part 27

 

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Dongfeng DFA1101GZ5AD6J-907. Manual - part 27

 

 

General Principles

GL-12

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

Clutch

CL

Table of Contents

Main Parameter............................................................................................... CL-1
Trouble Analysis............................................................................................. CL-2
Clutch Mechanical System ............................................................................. CL-3
Adjustment of Clutch Pedal............................................................................ CL-4
Clutch Cover and Flywheel ............................................................................ CL-6
Usage and Maintenance.................................................................................. CL-7

Clutch

CL-1

Clutch

Main Parameter

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 reservior.
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.

Bolt install hole size

Distributing diameter (mm)

Φ

368.3

Aperture (mm)

Φ

10.3 (+0.25) 

Number of holes

8 (4 pairs) 

Positioning pin hole size

Distributing diameter (mm)

Φ

363.53

Aperture (mm)

Φ

7.92 (0.03) 

Φ

9.52 (+0.03) 

Number of holes

2

Angle between positioning hole and installing bolt hole

15°

Friction lining size

D×d

Φ

325× Φ 200

Working pressure force

10250

Release bearing stroke (mm)

10

Pressure plate lift range (mm)

1.4

Height of release finger (mm)

56±1

Unbalance static of the cover assembly (g.cm)

50

Unbalance static of the driven disc assembly (g.cm)

25

Torque (N.m)

Max=770

Clutch

CL-2

Trouble Analysis

Trouble

Cause

Method

Clutch disengaged incom-
plete or vehicle started 
unstably

Clutch pressure plate or driven disc lin-
ing distorted or cracked
Release lever improper adjusted
Air in clutch hydraulic pressure control-
ling system pipe
Too large clutch pedal free travel 
Clutch master cylinder or booster 
worked abnormally

Change the pressure plate or driven disc 
lining
Disassemble and repair
Exhaust the air in the pipe

Readjust accord to the standard
Disassemble and repair

Clutch slipped

Clutchdriven disc friction lining or 
pressure plate worn
Oil stain on clutch driven disc or 
pressure plate
Too small clutch pedal free travel
Clutch booster push rod has no free 
stroke.
Clutch booster push rod can't return.

Clutch pressure plate spring failed
Clutch release bearing worn
Clutch booster push rod adjusted 
improperly

Replace driven disc friction lining or 
pressure plate
Clean driven disc friction lining and 
pressure plate
Disassemble and repair
Readjust accord to the standard

Check master cylinder push rod and 
booster oil seal
Change the pressure platespring
Replace the release bearing
Disassemble and repair

Abnormal sound of clutch

Clutch release bearing worn or 
improper lubricated
Clutch pressure plate or driven disc dis-
torted
Transmission input shaft or driven disc 
spline worn
Clutch pedal shaft bush worn

Replace the release bearing release bear-
ing
Change the pressure plate or driven disc

Replace input shaft or driven disc

Replace the bushing

Clutch pedal can't be 
stepped down

Clutch out of control
Cylinder of clutch hydraulic pressure 
system blocked
Release lever worn

Adjust
Adjust

Replace

Changes in clutch pedal

Air in hydraulic pressure pipeline
Master cylinder oil pipeline blocked

Exhaust air in the pipe
Clean or replace

Too large clutch pedal 
force 

Clutch booster troubled
Release shaft bushing blocked or 
improper lubricated
Release bearing flange blocked
Release lever bush improper lubricated

Disassemble, repair and clean
Replace bush or lubricate

Correct or replace the bearing flange
Lubricate

 

 

 

 

 

 

 

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