Dongfeng DFA1063DJ10 (14)-301/303. Manual - part 3

 

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Dongfeng DFA1063DJ10 (14)-301/303. Manual - part 3

 

 

General Principles

GL-8

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.

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

Volume Data

Part

Volume (L)

General Principles

GL-9

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 compo-

nent if its surface has the following abnormal signs: uneven wear, biased wear, scratch, crack, distortion, malfunc-
tion 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.

General Principles

GL-10

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.

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)

2. After engine started

3. During starting of vehicle

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

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

Abnormal sound

Clutch troubled
Transmission troubled
Propeller shaft troubled
Rear axle troubled
Engine drive belt slipped

General Principles

GL-11

4. During vehicle running 

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

Poor acceleration

Clutch slipped
Incomplete release of brake
Incomplete release of parking brake
Engine fuel system troubled

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

 

 

 

 

 

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