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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