Dongfeng Dfa1063dj10 14 301 303 Service Manual 2006 09
Full download: http://manualplace.com/download/dongfeng-dfa1063dj10-14-301-303-service-manual-2006-09/
DONGFENG DFA1063DJ10(14)-301/303
SERVICE MANUAL
DONGFENG AUTOMOBILE CO., LTD.
September. 2006
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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-
5~8 16~23 29~42 50~70 80~110 130~170 160~200 260~320
bon steel
High-strength
9~12 18~26 34~48 67~95 120~170 165~220 200~250 320~400
alloy steel
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 accord-
ing 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 Mileage Interval( × 1,000km）
Maintenance Item
△ 4 8 12 16 20 24 28 32 36 40 44 48 80
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 ★ ★
GL-3
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 ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
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 Mileage Interval( × 1,000km）
Maintenance Item
△ 4 8 12 16 20 24 28 32 36 40 44 48 80
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 Mileage Interval( × 1,000km）
Maintenance Item
△ 4 8 12 16 20 24 28 32 36 40 44 48 80
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 con-
trol mechanism ☆ ★ ★
Check the working conditions of the bearings in
gearbox ★
Disassemble and check gearbox ★
Suspension System
Maintenance Mileage Interval( × 1,000km）
Maintenance Item
△ 4 8 12 16 20 24 28 32 36 40 44 48 80
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 ★
GL-4
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 ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
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 Mileage Interval( × 1,000km）
Maintenance Item
△ 4 8 12 16 20 24 28 32 36 40 44 48 80
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 steer-
ing 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 neces-
sary ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Replace power steering transmission oil ★ ★
Braking System
Maintenance Mileage Interval( × 1,000km）
Maintenance Item
△ 4 8 12 16 20 24 28 32 36 40 44 48 80
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
General Principles
Braking System
Maintenance Mileage Interval( × 1,000km）
Maintenance Item
△ 4 8 12 16 20 24 28 32 36 40 44 48 80
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 Mileage Interval( × 1,000km）
Maintenance Item
△ 4 8 12 16 20 24 28 32 36 40 44 48 80
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 mech-
anism ★ ★
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 neces-
sary ★
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 above 4 ℃
10# light diesel above -5 ℃
20# light diesel between -5 ℃ ~ -14 ℃
35# light diesel between -14 ℃ ~ -29 ℃
50# light diesel between -29 ℃ ~ -44 ℃
Engine lubricant
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
Dongfeng Dfa1063dj10 14 301 303 Service Manual 2006 09
Full download: http://manualplace.com/download/dongfeng-dfa1063dj10-14-301-303-service-manual-2006-09/
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 Volume （L）
Fuel tank 120
Engine lubrication system 9
Engine cooling system 14.5
GL-7
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