Dongfeng DFA1101GZ5AD6J-907. Manual — part 26
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.
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.
Power steering gear
Add between the upper and lower scale of oil tank
Volume Data
Part
Volume (L)
General Principles
GL-9
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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