Dongfeng DFA1063DJ10 (14)-301/303. Instruction - page 1

DONGFENG DFA1063DJ10(14)-301/303

SERVICE MANUAL

DONGFENG AUTOMOBILE CO., LTD.

September. 2006

General Principles

GL-1

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.

General Principles

GL-2

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-

bon steel

5~8

16~23

29~42

50~70

80~110

130~170

160~200

260~320

High-strength

alloy steel

9~12

18~26

34~48

67~95

120~170

165~220

200~250

320~400

General Principles

GL-3

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 Item

Maintenance Mileage Interval( × 1,000km）

△ 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

★ ★