1

Preface

Thank you for using Dongfeng Brand mini truck. Dongfeng Mini Truck is the new generation product

manufactured by Dongfeng Vehicle Co.,Ltd., safety, reliable, comfort driving and high performance.

For better operation and maintenance the products, the operation manual is carried out. The book

introduces the driving operation, maintenance, assembly and regulation, malfunction analysis etc,.

Please read it carefully before operation, master the operation method quickly, maintenance and repair

the vehicle regularly according to the suggestion to ensure the security of truck, prolong the operation

life of vehicle.

With the development of technological progress, Dongfeng Mini Truck makes improvement and

perfection, and it may occur different between the Operation Manual Introduction with the actual

structure of vehicle, if any different, we will amend.

Dongfeng Vehicle Co., Ltd.

October, 2011

2

Statement

Dongfeng Vehicle Co., Ltd. will not responsible for the reliability, security and adaptability of the

vehicle if the following condition occurs:

1. Without permission, customer changes or modifies the design of machine;

2. Original spare parts, approved convertible parts or components instead by other parts;

3. Over loading during the operation.

Symbol stipulated in the manual as follows:

Note: It may cause personal injury or the damage for the parts and the vehicle if do not comply with

and pay attention to the matter which symbol stipulated.

Warning: It may cause serious personal injury or great property loss if do not comply with the

matters which Warning stipulated.

3

Content Ⅰ Overview of Vehicle .......................................................................................................................................... 5

Ⅱ Main Parameters ............................................................................................................................................... 6

1. Fuel ........................................................................................................................................................... 6

2. Location of Nameplate, VIN and Engine Number .............................................................................. 6

3. Vehicle Technical Parameters (Model EQ1040GLJ4-CMD1-D)....................................................... 7

Ⅲ Operations .......................................................................................................................................................... 8

1. Various devices and mechanism operations....................................................................................... 8

2 Vehicle use ................................................................................................................................................. 31

Ⅳ Maintenance and Inspection ......................................................................................................................... 37

1. Regularly safety precautions of routine maintenance ..................................................................... 38

2. Routine maintenance ............................................................................................................................ 39

3. Periodic Maintenance ........................................................................................................................... 39

ⅤMalfunction Analysis and Elimination ............................................................................................................. 53

1. Malfunction of Engine System (Please refer to Engine Operating Instruction Manual) ............. 53

2. Malfunction of Clutch System .............................................................................................................. 53

3. Malfunction of Gearbox System .......................................................................................................... 55

4. Malfunction of Compensating Gear System ..................................................................................... 56

5. Malfunction of Steering mechanism, Suspension, Wheel and Tire System ................................. 57

4

6. Malfunction of Braking System ........................................................................................................... 60

7. Malfunction of Power Supply System ................................................................................................ 62

8. All sorts of light fitting malfunction ...................................................................................................... 63

9. Accessories malfunction ...................................................................................................................... 66

Ⅵ Emergency Treatments .................................................................................................................................. 67

1. Tire replacement ................................................................................................................................... 67

2. Bridge connection starting ................................................................................................................... 68

3. Engine overheat .................................................................................................................................... 69

Ⅶ Body Maintenance .......................................................................................................................................... 71

1. Measures of protection ......................................................................................................................... 71

2. Vehicle interior cleaning ....................................................................................................................... 72

3. Body cleaning ........................................................................................................................................ 72

Ⅷ Fuel and Lubricating Oil, Vehicle Mounted Tools ....................................................................................... 74

1. Fuel/lubricating oil/coolant/scrubbing solution .................................................................................. 74

2. Vehicle mounted tools list .................................................................................................................... 75

5

Ⅰ Overview of Vehicle

Dongfeng mini truck is a new developed and designed product of Dongfeng Vehicle Co., Ltd.

The truck is the most ideal tool for short distance transporting in modern city and countryside with right

hand steering wheel and hydraulic braking truck. Unique outlook，novel modeling, flexible steering, good

stability, strong power, good mobility, small turning diameter, strong gradeability, high driving speed, low

noise, low fuel consumption, smooth and comfort running.

The humanized design of Dongfeng mini truck gives the driver to experience more driving pleasure; the

cab uses full seal structure. It has the natural ventilation system, various striking meters and indicators,

complete and convenient switches, graceful artistic color of the internal body, and the chair is designed

according to the modern human body engineering theory, comfortable riding and open vision.

6

Ⅱ Main Parameters

1. Fuel

It should adopt with different type of light diesel with the national standards under different

temperature.

When the ambient temperature is ≥4℃, it should use type 0 light diesels;

When the ambient temperature is <4℃, it should use type -10 light diesel;

When the ambient temperature is <-5℃, it should use type -20 light diesel;

2. Location of Nameplate, VIN and Engine Number

2.1 The data plate should be located at the middle of the internal cab of the right side column.

2.2 The vehicle identification number should hit in the middle front part of the frame right-side

7

beam.

2.3 The engine number is on the engine data plate.

3. Vehicle Technical Parameters (Model EQ1040GLJ4-CMD1-D)

Items Units Basic Parameters

Dimension

Overall dimension Length

mm

4700 Width 1770 Height 2100

Internal body dimension

Length 2800 Width 1650 Height 400

Wheel base 2850 Front tread 1400 Rear tread 1278

Rear suspension 1295 Weight Parameter Unload weight kg 1500

8

Loading weight 2320 Factory standard max. total weight 3950

No. of passengers(including the driver) person 2

Other Parameters Tire specification 6.00-14

Engine model/power/output volume YD480B/29kw/1809ml

Ⅲ Operations

The vehicle should be operated with the following requirements and methods.

1. Various devices and mechanism

operations

1.1 Door When the door opens from outside, insert the key to

9

the locking hole under the outdoor handle of the cab, turn the key, the door will be unlocked, and then draw the door handle, the door opens. As show in picture: Insert the key in the locking hole and turn it reversely to deadlock the door. It also works without the key, only have to press down the locking button, pull up the door handle, then close the door, the door deadlocks.

Locking buttons are set on all the door glasses; press this button, the door will deadlocks. At that

time, both outside and inside door handles could not open the door. As show in picture:

When the door opens, pull up locking button, then draw the handle, the door opens.

Warning Do not left the key in the car.

10

During travelling, take the key out of the ignition switch is forbidden.

1.2 Door Glass Lifter

The glass lifter handle is located inside of the door, the glasses will

raise or lower when turns the handle. As show in picture:

1.3 Chair

The chair divides into the seat back cushion and the seat cushion. The

seat back cushion fixedly installs on the chair bottom plate, the seat back cushion may turn over

forward, and rotation handle is in the flank of the chair. Behind the bottom plate, there are two

rotating joints fixed on the rear beam of the frame chair. Two hooks in front, the handle buckle are

installed on the front beam of the seat cushion in order to fix the seat cushion. The driver’s side

chair can be forward and backward moved.

11

1.4 Safety Belt Safety belt wearing (As show in picture)

Drawing the safety belt lock, pass the

should strap through shoulder, the belt

crosses the pelvis ,then press the lock into

the lock stand until hears “clicking” sound,

press down the red button on the lock

stand, the safety belt then will be unlocked. As show in picture:

Drawing the safety belt on the shoulder upward through the tongue, the shoulder slanting belt can

be adjust freely, the urgent locking mechanism of the safety

belt will suddenly stop or deadlocks during the impact. Safety belt checking (As show in picture)

Regularly check the parts including braid, lock catch, lock,

rolling-up, fixed point and guide ring, replace the damaged

safety belt and the one cannot work appropriately.

Warning

12

The driver and the passenger have to wear safety belt when the vehicle is travelling. The safety belt provides front part collision protection. The driver and the passenger seat at the front-row have to wear the safety belt during travelling to avoid injury from crashing or the fatal accident occurrence. The passenger is not allowed to seat in the cargo area, otherwise, once the accident occurs; they might get a more serious injury than the one who has fasten the safety belt at the seat.

The lower part of the safety belt should pass the pelvis, do not fasten

in the waist, the shoulder strip should fasten on the shoulder, do not

slip into the arm.

The safety belt cannot be twisted when wearing it, tightened comfortably with request. If the safety

belt is loose, the person will not be able to obtain the safe protection.

Make sure the safety belt lock catch inserts in the corresponding lock.

Do not fasten the safety belt on the clothes pocket with hard pieces or fragile, otherwise, when the

accident occurs, you may get injured from the goods fastened under the safety belt.

Regularly check the attrition and damage of the safety belt, it should be replaced if it is over wears

13

or damaged. After serious crash, should replace the used safety belt even it has no obvious

damage.

All safety belts after collision should be replaced (only if the accident is extremely small), even do

not looks obvious. If the unused safety belt does not satisfy the operation requirement or damaged,

it also should get replaced.

The safety belt should not get polluted from oil, chemical substance, especially the accumulator

electrolyte, may use moderate soap and clear water to clean the safety belt.

In order to prevent mobile relaxation when use the safety belt adjusting mechanism, the user is not

allowed to change or to add mechanism to the safety belt device.

1.5 The control device on the steering column

(1) Lighting Switch

The lighting switch has 4 positions (As show in picture)

LOCK

This is the normal parking position; the key can only take out in this

position. The ignition deadlocks once the key is take out.

ACC

14

When the key turns to this position, the radio and cassette player and the attached facility power are

connected, but the engine has no power.

ON

When the key turns to this position, all power in the vehicle are connected, the engine is at the start-up

condition.

START

When the key turns to this position, the engine starts, release the key, it will return to “ON” position

automatically.

Warning

Do not take out the key when the vehicle is moving, do not leave the child in the vehicle alone, and

remember to take the key. Without anybody’s looking after, the child is possible to cause the vehicle

move and causes injure.

Do not give the start-up motor to operate more than 5s for one start-up. If the engine does not work

and has not started, wait for 10s and starts again. If it does not work after several times, then check

the fuel and the ignition system.

Do not leave the key at the “ON” position if the engine is not turning, otherwise the storage battery

15

will be discharged.

(2) Combined Switch

The combined switch is located underneath the steering wheel (As show in picture), the left and

right multi-function control handle controls the front signal light, headlight, headlight variable light,

left and right steering light through different motion mode. The function of various marks on the

combined switch and the multi-function control handle are as follows:

16

Left Control Handle

This control stick is under the left side of the steering column, the operation is as follows:

(a) Revolving the handle at the end of the left control stick to turn on or turn off the light. There are 3

control positions on the handle: all lights are disconnected at “OFF” position; front position light, tail

light, plate light and meter light are connected at position, the headlight is not connected.

All above lights and headlight are connected at position.

When the headlight turns on, down press the control stick to transform into upper beam, up lift to the

middle position then transforms to low beam. When the upper beam connects, the upper beam

indicator on the meter will be connected. Up lift the control stick, the headlight will become the

variable light (returns when releases)。

(b)Steering Signal

Forward and backward moving control stick may connect to the left and right steering signal.

Turn right the forward push control stick, and turn left the backward pull control stick.

Right Control Handle

17

The control stick is at the right hand side of the steering column, it has 4 gears.

INT: The windshield wiper is the gap gear; the gear is extremely suitable for fog and light rain

weather.

LO: The windshield wiper operates in a stable low speed.

HIGH: The windshield wiper operates in a stable high speed.

OFF: The windshield wiper will stop operating if it does not work.

Upward lifts the control stick, spray the cleaning liquid, it restored immediately when releases, the

cleaning liquid spraying stops.

Warning

In the cold weather that the windshield is freezing, it should connect to the defroster device before

use the windshield wiper.

Do not use the cooler anti-freezing fluid as the windshield cleaning fluid, such may affect the vision

seriously, and will possibly damage the coating of the vehicle.

In order to prevent damaging the windshield wiper and the clean system part, please pay attention

to the following matters:

1. Do not attempt to use the windshield wiper for dust removal on the dry windshield, otherwise it

18

will scratch the windshield, and damage the windshield wiper piece. Use cleaning liquid to

moist windshield before use the windshield wiper, when the cleaning liquid does not blowout,

do not continue to run the windshield wiper, otherwise it will damage the wiper motor.

2. In winter, clean the ice and snow on the arm of the wiper before use the windshield wiper.

3. Check the windshield wiper system carefully before travelling, especially in bad weather.

4. When add the cleaning liquid, only add to 3/4 of the liquid storage tank volume in order to

ensure there has enough expansion space at the low freezing temperature when cleaning.

5. Use the qualified cleaning liquid that conforms to the stipulation.

(3) Horn

The horn button is located on the steering

wheel. When the power is connected, press

the horn button, the alarm rings.

1.6 Dashboard and Various Switches

(1) Holder (2) right control handle

(3)Combined dashboard (4) emergency

flashlight switch (5) left control handle (6)

19

other switches (7) radio and cassette player (8) central vent (9) heater switch (10) front cover

plate switch (11) ignition switch (12) lighter (13) ashtray (14) tool box

(1) Combined dashboard, speedometer, odometer

The speedometer expresses the speed of the vehicle by

Km/h

The odometer shows the total travel distance, the

smallest unit is 1Km.

Fuel Gauge

The fuel gauge shows the oil mass in the oil tank, when

the indicator at “F”, diesel is full in the oil tank. At position “E”, the oil tank has no diesel.

Water Temperature Gauge

Indicate engine coolant temperature. During travelling, the coolant temperature should maintain at

the normal range, the indicator moves towards “H” (high temperature) from “C”. If it surpasses the

scope of “H”, the engine is over heat, and then stops the vehicle immediately.

Left and Right Steering Indicator

20

When the ignition switch is connected to the steering switch at the connecting position,

indicator flashes, the steering light is also lightens, means it also gives the steering signal.

Left turns, the left indicator flashes; when right turns, right indicator flashes.

Headlight Upper Beam Indicator

The headlight uses upper beam, indicator lightens.

Warning Indicator

Emergency flashlight: press the emergency flashlight switch when emergency case occurs,

emergent stopping, send out the warning light to avoid crashing with the coming vehicles,

indicator flashes.

Warning Do not use this switch unless the emergency case occurs.

Oil Pressure Indicator

When the ignition switch is connected, indicator lightens immediately, after the engine is

21

start-up, flameout the indicator immediately. Otherwise, it shows that the engine sump oil level is too

low or the lubrication system has breakdown, then turn off the engine immediately to check the oil

level or replenishment. If the fault still has not fixed, should carry on the comprehensive inspection

to the lubrication system.

Charging Indicator

When the ignition switch is connected, indicator lightens immediately, flameout the indicator

immediately after the engine is start-up. Otherwise, there is fault occurs to the accumulator system.

Check if the fan breaks or looses first, if it is normal, then check the electric circuit.

Bake Fluid Level Light

Under the normal condition, when the ignition switch at the “START” position, indicator

lightens, if the light is not flameout when the engine starts or the indicator unusually connects during

traveling, these shows that the brake system has the fault, should check it immediately.

If the indicator unusually connects during travelling, drive the vehicle off the road to check the brake

22

system in the roadside.

Warning

It might need longer parking distance, bigger pedal force and longer pedal distance at that time

After inspection, if it is under the safe condition, drive the vehicle to the nearby repair shop with low

speed, otherwise should tow the vehicle to the repair shop.

Safety Belt Indicator When the ignition switch is connected, indicator lightens immediately. When the safety belt inserts to the fixed stand, the light disappears, it shows the safety belt is fastened.

Parking Brake Light When the ignition switch is connected, the parking brake light lightens if the parking brake is at the unreleased condition.

(2) Other Switches

Front and rear fog light switch Front Fog Light

Revolve the handle at the end of the left control handle at position , press the front fog light

switch, the light is on. When the front fog light lightens, press again, the light will be off. Rear Fog Light

23

Revolve the handle at the end of the left control handle at the headlight switch position, press the

rear fog light switch , the rear fog light is on, then press the “OFF” button, the rear fog light

will be off.

Lighter and Ashtray

When use the lighter, press the button, when automatically eject a standard after a few seconds, it

can be used once it draws out. Pull out the ashtray box when using, thrusts the ashtray after put in

the cigarette ash and the cigarette butt.

Attention:

The cigarette butt must extinguish when put in to the ashtray to

avoid the fire, and cannot put other sundry to the ashtray. Front Cover Plate Switch

Pull out the front cover plate switch handle under the right hand

side of the dashboard to unlock the front cover plate, and

then put the hand into the middle of the front cover plate to

lift the hook, lift up the front cover plate, and supports with

24

the outrigger. When close the plate, take down the outrigger

first, lay down the front cover plate slowly, and then push down

the front part of the plate, the front cover plate will be locked.

Tool box

Lightly lifts up the handle, the tool box then opens, jog the tool box

board to close it. Attention:

The tool box cover has to be closed to avoid anyone get injured when

traveling. Radio and Cassette Player

Basic Operation:

Under the off condition, the display

monitor shows the clock, lightly press

25

the power button on the plate to start the power, and under the starting condition lightly press the

power button to turn off the power. Press volume+ and volume- to adjust the sound. Press up and

down button to change tracks. This player also supports arbitrary track insert playing. Inserts the

USB or SD/MMC willfully, the song will played automatically.

Heater System

(1) Unidirectional ventilation ---- blows

the face

The wind is sending out through the

dashboard central vent and the side

vent.

(2) Bidirectional wind

The wind is sending out through the

dashboard central vent and the bottom vent.

26

(3) Unidirectional blast----blows the leg

The wind is sending out through the floor air vent

(4) Defrost and blows the leg

The wind is sending out through the floor air vent, it has few winds sending out through the

windshield defrost air vent and the side defrost air vent.

(5) Defrost

The wind blows from windshield defrosting vent and side defrosting vent.

(6)Internal and external circulation control button

The internal and external circulation of air is controlled by the button.

(7)Temperature control buttons

Control temperature of cold air (blue)/warm wind (red).

(8)Air volume choice button

It is used in air regulation.

(9)Ventilation position choice button

27

The warm wind can be selected to blow from the above vents by pressing the button.

1.7 Other control device

(1) Brake parking lever

When parking, brake rod is pulled and wheel brake is blocked. Then

the parking brake is released and operator needs to press the button

on top of brake bar and then replace the bar.

Warning:

When leaving the car after parking, parking brake must be used. At that time, transmission should

be in reverse gear or gear 1. The car cannot be used when the parking brake is blocked, otherwise

there will be permanent damage to the braking system.

If the parking brake cannot be blocked reliably or

unlocked, the car needs repairmen.

(2) Pedal

○1 clutch pedal ○2 brake pedal ○3 accelerator pedal

28

Attention:

Unless necessary, don’t put your foot on the clutch so

as not to wear.

(3) Gear lever

First gear: Bring to the left and then push forward.

Second gear: bring to the left and then pull backward.

Third gear: push forward when in the central position.

Fourth gear: pull backward when in the central position.

Fifth gear: bring to the right and then push forward.

Sixth gear: bring to the right and then pull backward.

(4) Fuel tank filler

When refueling unlock fuel tank tap and fasten it tightly after use.

Warning when refueling one should uncover the lid slightly for fear of fuel discharging.

(5) Sunvisor

29

Sunvisor is equipped to block the sunlight and ensure driving safety.

(6) Interior mirror

Interior mirror can be turned up and down along the central axis.

(7) Exterior mirror

Driver can see the vehicles and objectives through the mirror.

(8) Safety handle

Handles are installed at the side wall of seats (except driver’s seat)

Warning

Passengers should strain the handles.

Nothing can be hung on the handles so as not to block driver’s view.

(9) Vehicle-mounted tools

One set of tools is available to repair at any time.

(10) Engine cabin

When opening the cabin:

30

A. put the seat back to the seat cushion.

B. unlocks the two hangers.

C. lifts the seat slowly and then fixes it.

D. use the opposite way to close.

Warning

When opening or closing，one should be raise or lay down the seat slowly. After opening the cabin,

make sure seats and back are adjusted to the right place and deadlock the seat.

(11) Car body

Ternary doors design is employed.

Warning When driving the floor of car cannot be lay down to avoid influencing the indicator light and

causing accidents.

31

2 Vehicle use

2.1 waste gas warning

Waste gas is filled with CO gas, harmful deadly gas, which is difficult to test. We must pay attention

to following points to avoid waste gas:

Engine is not allowed to operate in the garage or any closed region.

Snow and leaves should be cleared out of the vent frequently.

Regular inspection should be done for exhaust system.

2.2 Starting engine

Before starting engine, we should ensure that braking is locked and gear lever is in the neutral

position. Spin the ignition key to “ST”position and connect starting dynamo until the starter fires

and operates.

Warning

Starting motor should be stopped and the key should be released after the engine is started.

32

Starting motor should be stopped when the starting system is out of order.

The time for starting motor should be less than 5 seconds. If it fails, restart it after 10 seconds.

Don’t idle the engine with high speed after it starts.

When starting, push down the clutch pedal and make the transmission to first gear. Then let go the

parking brake, push the pedal down and release the clutch slowly.

2.3 Transmission use

All the forward gears adopt synchronizer ensuring smooth shift. Before shifting, the clutch should be

separated completely.

Before running on downhill or steep hill, the speed should be reduced and low gear should be used

with engine braking. Long distance brake of braking system should be avoided so as not to make it

overheating and invalid.

When walking on the smooth road，walk slowly before changing to low gear. Sudden change of

engine speed may make the vehicle skid.

Attention

33

Don’t push down the clutch pedal for a long time to avoid the damage. When shifting, one needs to

push the pedal completely.

2.4 Brake

The vehicle’s braking distance increases along with the driving speed. We should make sure that

the vehicle has enough distance before parking.

Warning

There will be screaming when braking which needs inspection.

Don’t use continuous brake for long time or push down the pedal when walking.

When water is flowing into brake drum, the brake will become invalid. Therefore, when the vehicle

travels through water or after it has been washed, we should push down the pedal slightly at low

speeds, operate the brake repeatedly and make the brake dry and recover.

Clean the brake after walking on sandy road to avoid wear.

Vacuum booster is employed to ensure smooth brake.

34

2.5 Running in

In run-in period, we should operate carefully to maximize its performance. We should comply with

the following instructions within the first 1000 km range:

1. Don’t run the engine with high speed after starting. It needs warming up.

2. Don’t run at fixed speed. If frequently changing speed, the moving parts can get good run-in.

3. It is strictly prohibited to urgent acceleration.

4. Avoid sudden braking as far as possible.

5. Don’t walk slowly at high gear.

6. Don’t use trailer in the run-in period.

7. Try to avoid walking on mud or sand roads.

2.6 High-speed precautions

a. The higher the driving speed is, the longer the braking distance is. As a result, the braking pedal

is controlled depending on the driving speed and needed braking distance.

35

b. When passing the mountain pass or portal, the vehicle will be influenced by lateral tuyere; we

need to reduce the speed to avoid unexpected vibrating.

2.7 Driving on slope

You have to change down when you drive uphill to avoid the overload of engine.

Pay attention to the following points:

a. You have to change down when you drive uphill to increase engine torque. Shifting should be

rapid and timely for fear of flameout of the engine.

b. When running downhill we need to shift down using the engine to brake.

c. Always don’t make the engine speed too high.

2.8 Driving on slippery surfaces

When walking on the wet or snowy roads, the adhesion of tyre and ground will be decreased losing

control of steering and braking. Therefore driving at high speed is forbidden.

Attention:

36

a. Don’t use wore tire. By Necessity, we must reduce the speed.

b. Always keeps low speed avoiding sharp turn, nasty start and emergent braking.

2.9 Economic driving

We can improve fuel economy as following:

(1)Avoid too much idle speed

If we need to wait for a long time, we can stop the engine using parking brake.

(2)Avoid rapid start

Rapid start will increase unnecessary fuel consumption.

(3)Avoid unnecessary parking

Avoid unnecessary parking.

(4)Keep the cleanness of air cleaner

If the air cleaner is too dirty, the air input will be reduced causing incomplete combustion and fuel

waste.

(5)Keep regular load

37

Overload will cause much fuel consumption.

(6)Keep normal tire pressure

Low tire will increase running resistance waste fuel.

2.10 Load

Don't let vehicles overload.

Ⅳ Maintenance and Inspection

We need to maintain the vehicle in a planned way, strengthen inspection and adjustment and

ensure that the vehicle is in good condition.

The maintenance of vehicle consists of routine maintenance and periodic maintenance which is

divided into Grade I, Grade II and Grade III.

38

1. Regularly safety precautions of routine maintenance

Be careful doing inspection and maintenance. Pay attention to following points:

1) Don’t start engine in garage or other prohibited area.

2) One needs to pull up hand brake and put the transmission into the neutral position if it is

necessary to start the engine for maintenance.

3) When the engine is running，hands, cloths, tools and other objects should be kept away

from the rotating fans and belts.

4) Don’t touch high-temperature parts such as exhaust pipe of engine and silencer.

5) No smoking around diesel oil or battery for fear of fire.

6) When using lifting jack one cannot get to vehicle bottom.

7) Pay attention to connect anode and line in a right manner to avoid short circuit.

8) When cleaning and maintaining, prevent the water from getting into control module.

39

2. Routine maintenance

Routine maintenance for the machine is the mandatory daily work, main contents:

a. Insists on inspecting safety mechanism and connections of parts before, between and after

driving.

b. Keeps the cleanness of machine oil, air filter and battery.

c. Avoids leakage of water, electricity, gas and oil.

Through inspection we can take targeted measures.

3. Periodic Maintenance

3.1 Regular maintenance projects and due time

The following two tables set Kilometers traveled or months as maintenance time,

Maintenance symbols:

40

G---replace

R---lubricate

X---wind to certain torque

J---inspection

T---regulate

(1) Regular maintenance projects and due time

Due time

project

km 10 20 30 40 50 60 70 80

months 6 12 18 24 30 36 42 48

Empty filter cement or the

asphalt pavement

clean every 10000km, replace every 40000km

Empty filter sand road clean every 2500km, replace every 4000km

Fuel tank. oil tube and J.T --- --- J.T.G --- --- --- J.T.G

41

coupling

Fuel filter G G G G G G G G

Electrical wiring, coupling and

light

--- J.T.G --- J.T.G --- J.T.G --- J.T.G

clutch J.T J.T J.T J.T J.T J.T J.T J.T

Brake fluid(liquid level,

leakage pollution)

J.TG J.T.G J.T.G G J.T.G J.T.G J.T.G G

Brake pedal(stroke) J.TG J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G G

Hand lever and dragline J.T J.T J.T J.T J.T J.T J.T J.T

Brake drum and brake shoe

(abrasive)

J.TG J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G

Brake hose and pipeline

(leakage damage)

J.TG J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G

42

tire(abnormal wear and air

pressure)

J.TG J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G

tire nut(damage.

compactness)

J.TG J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G

Bolts and nuts(compactness) --- X --- X --- X --- X

Steering gear(gap.

compactness)

J.TG J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G

(2) Maintenance for bad driving conditions

If your vehicle is used in bad conditions, you can refer to the following table for maintenance.

Bad conditions parts Maintenance interval

BC driving belt J.T.G 10000km or 6 months

ACDE engine oil and oil filter G 5000km or 3 months

BC driving belt J.T.G 10000km or 6 months

43

ACDE engine oil and oil filter G 5000km or 3 months

ABD Exhaust pipe and the device J.T.G 10000km or 6 months

C air cleaner cartridge J.T.G 2500km or 3 months

BE Transmission and nut G 20000km or 12

months

B Chassis bolts and nuts X 10000km or 6 months

ABC brake drum and brake shoes J.T.G 10000km or 6 months

A: repetitive short-range running

B: run on the rough and muddy road

C: run on the dusty road

D: run on the extremely cold or salt road

E: repetitive short-range running in very cold weather

3.2 Regular service content

44

(1)Instrument and indicator lights

Turn the ignition lock to connecting position. Test indicator light and fuel meter. After starting the

engine, test indicator light and water temperature gauge. After driving, test the milometer.

(2) Lights

Check the lights are functional or not.

(3) Speaker, Directional signal, wiper and scrubber

Check speaker, Directional signal, wiper and scrubber function is normal or not.

(4) Door lock

Check the door lock function is normal or not.

(5) Internal and external mirror

Check whether we can get good rear vision on driver’s seat and adjust.

(6) License tag

Check whether the tag is clean, fixed and legible.

(7) Suspend

45

Check whether the vehicle suspends and repair if it is necessary.

(8) Fan belt

If the fan belt is too loose, it will cause overheating of belt and premature wear. Use your thumb to

press the belt, there will be 6-8mm sinking.

Belt adjustment and replacement

a. Stop the engine

b. Loosen the bolts which connect the engine.

c. When tightening belt，push the engine outward and tighten the bolt until the compactness fits

the needs.

d. When replacing belt，loosen the bolt，push the engine inward and replace the belt.

(10) Engine lubricating oil should select specified oil according to temperature.

Oil surface check: The correct amount of lubrication oil is important for the lubrication of engine. Put

the vehicle on a level surface，take off oil level indicator，clean it and get into oil hole which should

46

be between the scales. Again into the oil hole, should be between scales. If near the referral, we

should apply after filling oil, start the engine and idle running for a while, and then check a ruler.

Machine oil replacement

Release the oil after the engine stops when the oil is still hot.

47

Before dismantling refueling mouth screw, feel the temperature by hand and twist off when it is cool

enough. Unused or used oil should be kept in safe place.

(11) Gear oil

When you add or replace transmission or differential gear oil please adopt the oil below:

Item Oil type Recommended oil

transmission APL.GL-4 SAF75W-90

Differential APL.GL-5 SAF80W-90

Oil position check

Refer to the steps:

a. Put the vehicle on a level surface and strain hand shake.

b. Dismantle the refueling mouth screw.

c. put your finger into oil outlet to feel the amount of oil.

d. Mount refueling mouth screw.

Warning

48

After driving the temperature of gear oil will be high. Before dismantling refueling mouth screw, feel

the temperature by hand and twist off when it is cool enough.

Gear Oil Exchange

When changing oil, follow the following steps:

a. Tear apart the drain access plug

b. Tear apart the purge cock to exhaust the oil and reinstall the purge cock.

c. Choose the seasonable oil and fill it into the assigned position from the oil filler.

Attention: When wresting the plug, please using the GY-210 seal gum to prevent leaking.

(13) Motor Liquid Coolant

If the liquid coolant is not enough, it needs to filling-up. It is dangerous to open the heat radiator

when the motor is hot; you should open it when the motor is cooling-down.

(14)Glass Scrubbing Solution

Don’t use antifreeze in the windshield washing tank, which will influence the view and maybe

damage the paint layer of the truck.

49

When there is no water in the washing tank, do not work, otherwise, it will damage the electric

motor.

(15) Air Filter

If the air filter is clogged by the dusts, it will increase the inhalation resistance, so the motor power

will be decreased and the oil wear will be increased. You must clean and change the filter element.

Cleaning method: lift down the lid of the air filter and take out the filter element and use the

compressed air to blow away the dusts above the filter element.

(16) Brake Fluid

The fluid level should be between the highest and the lowest fluid level. You should add the same

brake liquid when the fluid level is low.

Warning

If the liquid level of the brake fluid reservoir is too low, the light on the

instrument desk will be lighted to prompt filling-up.

50

Don’t use different brands brake fluid, outdated and no-lid container brake liquid.

(17) Brake Pedal

When the brake pedal is treaded forcefully, the distance A (see as the picture) between pedal and

anterior wall cannot less than 95mm. When the following situation happens, it shall be maintained:

a. Lack of brake force

b. Unsteady of brake

c. Block of brake

d. Have brake noise

e. When treading the pedal, the pedal kicks.

(18) Clutch Pedal

The free stroke of the clutch pedal is 15-25mm; too long or too short is not suitable.

(19) Tire

In order to avoid the unbalanced wear and tear to prolong the operation life, the tire should be

exchanged as per 10000 km. When exchanging, you should readjust the pressure of front and rear

51

tires. When the tire is inflated, you should inflate it and meanwhile check the pressure to the

assigned position.

When using the tire, you should do the following checking:

a. To check the wear and tear situation of the tire tread so as to ensure whether it needs change.

b. Whether there is inordinate wear or not, fish mouthing and impairment of tire.

c. Whether there is any iron nail or not, stone or other stuff penetrating into the tire or tread.

d. Whether there is rapping of wheel nut or not.

(20) Accumulator

If the battery electrolyte always needs to keep between the high order and low order, it should

replenish electrolyte till to the high order line. When the post head appears white powder, it should

be washed out by mild water, then daubing up the consistent lubricant. However, please pay

attention to that don’t wet the accumulator. Every month, the accumulator should be in charged so

as to prolong the operating time.

Warning

52

When inspecting and maintaining, you should switch off the ground lead to avoid short circuiting.

(21) Screen Wiper

If the wiper blade is with brittle fracture or broken, it should be changed immediately and in order to

avoid brush burn to the glass, please don’t brunt glasses when you demount the blade.

(22) Parking Brake

When parking brake is dead locked, the number of teeth which ratchet wheel can tell should be

more than 7. If within this range, the brake cannot be completely deadlocked or unlocked, you

should check it.

(23) Steering Wheel

To turn the steering wheel from left to right slowly until you can feel a little bit resistance force, then

measure the rotating distance which should be within the assigned value. On the flat and wide land,

you turn the steering wheel from left to right until it cannot move to see if it is easy and convenient to

steer. The play of steering wheel is 0-30mm. If it exceeds the play range, the wheel should be

inspected and adjusted.

53

ⅤMalfunction Analysis and Elimination

1. Malfunction of Engine System (Please refer to Engine Operating Instruction Manual)

2. Malfunction of Clutch System

Problem Cause Solution

Clutch Track slip

Free stroke of pedal is too short Adjust

The friction wafer is fraying and with

greasy dirt

Change or Clean

Clutch pressure disk or flywheel face is

distorted

Change or repair

The pressure of diaphragm spring is not

enough

Change

54

Declutch of clutch is not

thorough

Free stroke of pedal is too long Adjust

Diaphragm spring is weaken Change

Pitting of the input shaft spline Lubricate

Damage or abrasion of the input shaft

spline

Change

Rapture of pull-off spring Change

Clutch Shudder

Abrasion of friction wafer Change

Rapture or damage of pull-off spring Change

Lacking oil or damage of release bearing Change or lubricate

Differential pressure of diaphragm spring Change or adjust

Rivet rapping of friction wafer Repair or change

55

3. Malfunction of Gearbox System

Problem Cause Solution

Out of gear

Abrasion of gearshift shaft Change

Abrasion of synchroshifter gear sleeve Change

Weakness or damage of guide spring Change

Bearing abrasion of input shaft or basic shaft Change

Difficult to shift the gear

Declutch of clutch is not thorough Adjust

Unsuitable adjustment by operating gear Adjust

Abrasion of chamfering on gear sleeve or

gear

Change

Deformation of gearshift shaft Change

Noise Lack of grease oil or unsuitable kind Replenish or change

Damage or abrasion of bearing Change

56

Damage or abrasion of gear Change

Damage or abrasion of synchronizer gear

ring

Change

Abrasion of chamfering on gear sleeve or

gear

Change

4. Malfunction of Compensating Gear System

Problem Cause Solution

Gear noise

The gear compound is deteriorate or wetted Change oil and

filling-up

The clearance between drive gear wheel and follower

gear is not matched

Adjust

Drive gear wheel and driven gear is not match Adjust or change

57

Rapping of fixed bolt on driven gear Adjust

Damage of half axle gear or drive gear wheel on

compensating gear

Change

Bearing noise

The gear oil is deteriorated or wetted Change oil and

filling-up

Drive gear wheel bearing is damaged Change

Half shaft bearing or rear axle bearing is damaged Change

Oil leakage

Breather plug is blocked Clean

Oil seal is abrasive or damaged Change

Too much oil Adjust

5. Malfunction of Steering mechanism, Suspension, Wheel and Tire System

Problem Cause Solution

58

Off tracking of wheel

The tire is abrasive Change

The tire pressure is not suitable Adjust

The front wheel is out of position Adjust

The front and rear plate-form spring is

misplaced or ruptured

Adjust or change

Inordinate wear or excessive

wear of tire

The front wheel is out of position Adjust

The truck is overloaded Check

Bush bearing is abrasive or rapping Check

The wheel or tire is waggling Check

The tire pressure is not enough Adjust

Wheel hop The tire is with bulge or damaged Change

Shimmy of front wheel The turning track rod is abrasive Change

The tire is with bulge or damaged Change

59

The drag link is rapping or abrasive Adjust or change

Difficult turning

The tire pressure is not enough Gasing to the prescribed

value

The front wheel is out of position Adjust

The front axle is overloaded Alleviate loading

Steering post is clamping stagnation Check and adjust

The truck is low or not

accordant

The plate-form spring is misplaced or

ruptured

Adjust or change

Overloaded Alleviate loading

Plate form spring is cracked

Too much emergency braking, the

speed is too fast on unsteady road

Avoid emergency braking,

reduce the running speed

on bad roads

U-bolt is rapping Adjust

60

The dash pot is out of efficiency Change

It is noisy when driving

The rubber articles of the suspension

system is ageing or damaged

Change

Not maintenance on time Keep maintenance on

time

6. Malfunction of Braking System

Problem Cause Solution

Weak braking force Brake pipe leaks oil Check and change

There is greasy dirt or water between

brake drum and shoe plate

Clean or change

The arrester is overheat Repair or change

The brake shoe is abrasive change

61

The wheel braking cylinder is abrasive change

There is air in the system exhaust

Non-uniform of braking There is greasy dirt or water between

brake drum and shoe plate

Clean or change

The brake clearance is not matched Adjust or change

The tire pressure is uneven Gasing

The fluid flowing of brake pipe is not

smoothy

check and change

The suspension element is rapping check and adjust

The pedal travel is too long Local fault of braking system check and adjust

Lacking of braking fluid of liquid

storage pot

filling-up brake fluid

There is air in the braking system exhaust

62

Malfunction of brake returning

The plunger of master pump cannot

return correctly

check and change

The return spring in the arrester gear

cannot return

check and change

The wheel piston cylinder is jammed check and adjust

The braking warn light is

lighted after motor starts up

Lacking of braking fluid filling-up

Brake pipe leaks oil check and change

Malfunction of warning light circuitry check and adjust

When parking braking, the

braking light is not lighted

Malfunction of circuitry check and adjust

7. Malfunction of Power Supply System

Problem Cause Solution

63

When the motor stops, the

charging light is not lighted

The Backup fuse is burn out Check and change

The light is burnout Change

The wire joining is loose Check and adjust

The electric brush or the slip-ring is

with poor contact

Check and repair

The motor is working but the

charging light is not blanking

The driving belt is loose Check and adjust

Malfunction of electric generator Check and Repair

Malfunction of circuitry Check the circuitry

8. All sorts of light fitting malfunction

Fault Reason Solution

Front lamp off Lamp bulb damaged Replace

Switch fault Check and repair

64

Fuse blown Replace

Lead wire or earthing fault Repair

Front and rear fog lamp off

Lamp bulb damaged Replace

Fuse blown Check and repair

Switch fault Check and repair

Lead wire or earthing fault Repair

Backup light off or can’t be

turned off

Lamp bulb damaged Replace

Fuse blown Check and replace

Backup switch fault Check and replace

Lead wire or earthing fault Repair

Braking lamp off

Lamp bulb damaged Replace

Fuse blown Check and replace

Backup switch fault Check and replace

65

Lead wire or earthing fault Repair

Steering lamp off

Directional signal, alarm relay fault Check and repair

Combination switch or alarm switch

fault

Check and repair

Fuel indicator, water

temperature gauge don’t work

Fuse blown Check and replace

Measurement unit fault Check and replace

Fuel indicator fault Check and replace

Lead wire or earthing fault Repair

sensor Check and replace

When the brake fluid is too

low, the alarm is not on.

Lamp bulb damaged Check and replace

Fuse blown Check and replace

Line fault Check

Brake level switch fault Check

66

9. Accessories malfunction

Fault Reason Solutions

Wiper malfunction or non

homing

Fuse blown Check and replace

Electric motor fault Check

Switch fault Check

Lead wire or earthing fault Repair

Scrubber malfunction

Rinse the hose or nozzle blocking Clean or replace

Electric motor Check

Switch fault Check

Lead wire or earthing fault Repair

Cigarette Lighter malfunction

Fire switch fault Check

Cigarette Lighter fault Check

Lead wire or earthing fault Repair

67

Ⅵ Emergency Treatments

1. Tire replacement

1) Take out the jack from the vehicle amounted tools

2) Stop the vehicle on the flat solid ground, if the vehicle stopped on the road, turn on the

emergency flash

3) Lock the parking brake, make shift level into

reverse gear, and fix it with hard objects under

the wheel.

4) Loosen the wheel nut by the wheel wrench, but

do not remove it.

68

5) Put the jack under the jacked part; jack the vehicle slowly and smoothly.

6) Remove the nut and tire, install the new tire and fix the nut by hand.

7) Lower the jack, tighten up the nut in the cross order by the wrench.

2. Bridge connection starting

When the vehicle is unable to start, please use the following method：

(1) Use 12V battery lap start the vehicle, place another good battery in the vicinity of your vehicle in

order to take the enough wiring length. Lock the hand brake of the vehicle.

(2) Connect one end of the wire to the anode of the battery; connect the other end to the anode of

the rescue battery.

(3) Connect your second wire to the cathode of the rescue battery; connect the other end to the

unpainted connection metal parts of the engine from the power shortage vehicle.

Warning

69

Do not directly take the bonding jumper wire connected to the power shortage battery cathode, as it

may produce an explosion.

3. Engine overheat

The starter fault:

(1) Turn the ignition switch to START location, turn on the headlamp, if the lights is very dark or

gradually go out, it indicates that battery has power shortage or poor contact between electrode

wires.

(2) If the headlamp runs properly, check whether the fuse is fused.

Engine overheats:

(1) In the process of moving, if the water temperature table displays the temperature is too high, do

as the following:

70

a. Park the vehicle in a safe place.

b. Make the engine do the idle running for several minutes till the water temperature

between “H” and “C”.

(2) If the water temperature gauge indicates no drops:

a. Turn off the engine; inspect the water pump belt for damage or slipping.

b. Inspect the radiator to check whether the radiator, water pump and water pipe have

water leakage or not. If do, don’t start the engine.

c. If no water leakage, fill right amount of cooling fluid.

Warning

If you hear or see a steam leak, drive the car to a safe place, stop the engine and make it cool. Do

not open the engine compartment. When you are not able to see or hear the steam out, open the

radiator cap to check whether it is boiling, open it after it cooled.

71

Ⅶ Body Maintenance

1. Measures of protection

In order to prevent your vehicle from corrosion, here are several kinds of corrosion causes of automobile for your reference:

(1) Salt, dirt, moisture and chemical substance accumulated in the vehicle floor or the part of the car

frame which is difficult to touch for a long time.

(2) Paint peeling, injuries or other damage are the causes of corrosion.

(3) High temperatures will accelerate corrosion speed.

(4) Some part of the truck will accelerate corrosion speedily if stay in the wet environment for a long

time.

How to avoid the corrosion?

Keep the truck clean & dry. Clean the dirt in truck, don’t park truck in damp, poorly ventilated place.

72

2. Vehicle interior cleaning

At the time of cleaning the car, do not use the spray diluents or other flammable materials; do not

use bleach or strong-alkaline household cleaners.

Vinyl resins of decoration

Light wipe the decoration with a sponge or soft cloth using wet-water and a small amount of soap or

gentle cleanser, after a few minutes, light wipe it clean by a clean soft cloth with water.

Fiber material cleaning

Clean the dust with vacuum cleaner, wipe the dirty place with a clean dip mild soapy cloth, and

wash it with clean water after cleaning.

3. Body cleaning

Don’t clean or wax the car when the engine is running.

73

3.1 Rinse away the sand and gravel on floorboard or wheel with high pressure water gun.

3.2 When washed the car exterior, wipe with soft cloth, don’t use hard objects do the cleaning to

avoid abrasion on the vehicle surface.

3.3 Take some cleanser with the soft cloth, wipe lightly on the car surface when washing the car.

3.4 Wash with water once it cleaned.

3.5 After cleaning, wipe the water beads with a soft cloth, making them natural dry.

74

Ⅷ Fuel and Lubricating Oil, Vehicle Mounted Tools

1. Fuel/lubricating oil/coolant/scrubbing solution

Item Using part Specifications

Fuel Fuel tank 0# light diesel oil

Lubricating oil

Engine SE grade 10W/30(for winter)

SE grade 20W/50(for summer)

Transmission Gear oil 75W/90 GL-4

Rear axle differential Gear oil 80W/90 GL-5

Coolant radiator Antifreeze solution 82E-40(CA-01)

Scrubbing solution Scrubbing solution tank ZT-30

Braking fluid Braking system GB10830JC3 grade

75

2. Vehicle mounted tools list

No. Spare parts No. Spare parts Quantity

1 39C-01031 Double opened wrench（S8×S10） 1

2 39C-01033 Double opened wrench（S13×S16） 1

3 39N-01033 Double opened wrench（S16×S18） 1

4 39C-15010 Small wrench 1

5 39C-01100 Phillips screwdriver assembly 1

6 39C-01120 One glyph screwdriver assembly 1

7 39C-01140 Carp clamp assembly 1

8 39C-01146 Tire pry bar and Jack rocker 1

9 39D-01058 Wheel socket nut wrench 1

10 QYL5 5T oil pressure jack 1