Dongfeng DFA1101GZ5AD6J-907. Manual - part 28

 

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Dongfeng DFA1101GZ5AD6J-907. Manual - part 28

 

 

Clutch

CL-3

Clutch Mechanical System

1.Clutch pedal bracket assy
2.Lower fixed plate--pedal bracket
3.Hose assy--oil reservior to master cylinder
4.Clutch pedal welding assy
5.Pedal sleeve
6.Clutch pedal shaft
7.Clutch pedal return spring
8.Bush--pedal assy
9.Pin
10.Clutch master cylinder assy
11.Oil reservior assy

12.Front oil pipe assy
13.Free flowing coupling
14.Front  hose assy--clutch
15.Rear oil pipe assy--clutch master cylinder to 
booster
16.Clutch rear oil pipe bracket
17.Rear  hose assy
18. Booster assy
19.Nylon pipe assy (air pipe to four-way protective 
valve)
20.Bracket set--clutch booster

Clutch

CL-4

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.

Clutch driven disc and pressure plate

Clutch driven disc

1.Friction lining rivet
2.Friction lining
3.Wave spacer
4.Front damping disc
5.Wave spacer rivet
6.Damping spring

7.Damping spacer
8.Disc hub
9.Damping impact spacer
10.Damping spring spacer
11.Limiting pin
12.Rear damping disc

Clutch

CL-5

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.

Overmuch 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 dia-

phragm)

If the height is not in the range of the specific range, you need to

replace the pressure plate.

Shake the pressure plate gently, listening and check the wear or dam-

age of the diaphragm supporting ring. Or you can knock the rivet head
gently to find if there is cracks. Replace the pressure plate if necessary.

Check the surface of the pressure plate for any ablation or 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 distorsion or damage, and replace them if necessary.

Adjust the plainness of the diaphragm by tools.

            Plainness: <0.7mm

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 acrossed sequence, following two steps.

Clutch

CL-6

Clutch Cover and Flywheel

1.Driving blade
2.Rivet--pressure plate
3.Rivet--cover
4.Rivet--supporting ring
5.Supporting ring

6.Diaphragm spring
7.Pressure plate
8.Clutch cover
9.Balancing rivet

 

 

 

 

 

 

 

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