DFSK Extended Cab Service Manual

2019 DFSK Extended Cab Truck
- Service Manual -
IDENTIFICATION OF THE VEHICLE
Contents
Ⅰ. Identification of the vehicle
1. Identification of Number
2. VIN
3. Serial Number of the Engine
Ⅱ. Main Technical Parameter

A. Parameter of Mini Bus
1. Engine Parameters
2. General Function Index
3. Fuel consumption
4. Main Parameters
-2-
5. Main weight Parameters
6. Wheel Alignment Parameters
7. Tyre Air Pressure
8. Capacity Parameters
9. A/C System Parameters
B. Parameter of Mini Truck
1. Engine Parameters
2. General Function Index
3. Fuel consumption
4. Main Parameters
5. Main weight Parameters
-3-
8. Capacity Parameters
Ⅲ.Vehicle Devices & Mechanics Operation

1. Door
2. Key
3. Front door window
4. Front door
5. Rear door window
6. Seat
7. Safety Belt
8. Dashboard
9. Fire switch
-4-
10. Lighting, turning and high/low beam control pole

11. Wiper and cleaner control lever
12. Rear wind window wiper and cleaner switch
13. Horn
14. Emergency light switch
15. Fog light switch
16. Heating system
17. Control Board of heating system
18. Assembled meter
19. Cigar lighter
20. Cigarette ash box
21. Stereo radio
-5-
22. Tool box

23. Inner light & interior rear view mirror
24. Interior top lamp
25. Outside rear view mirror
26. Sun shading board
27. Safe handgrip
28. Tool kit
29. Brake rod by hand
30. Pedal
31. Shift handlebar
32. Front store house cover
Ⅳ. Operation of the Vehicle
-6-
1. Running-in
2. Start of the engine
3. Safety driving
4. Brake
5. Economy driving & environmental adaptability
Ⅴ. Guide for Vehicle Operation
1. Fuel
2. Generator strap
3. Compressor belt
4. Engine oil
5. Engine belt
6. Coolant Trademark
-7-
7. Thermostat
8. Transmission oil
9. Gasoline filter & oil supply tube & oil return tube
10. Air cleaner
11. Spark plug
12. Oil sprayer
13. Throttle valve block
14. Three-way converter
15. Electric fuel pump
16. Steering operation
17. Clutch pedal
18. ABS
-8-
19. Brake system

20. Tyre
21. Battery
22. Fuse
23. Air window cleaning liquid
24. Replacement of Bulb
25. ECU
26. Ignition timing
27. Usage of Jack
28. Extinguisher
29. Triangle warning plate
30. Operating controller
-9-
31. Turning over and side

Ⅵ . Check & Maintenance Service
1. Daily inspection
2. Regular check and maintenance
3. Regular maintenance period and items
4. Signs for maintenance
5. Maintenance
Ⅶ. Analyzing & Eliminating the Malfunction
1. Malfunction of engine system
2. Clutch Problems
3. Malfunction of transmission
4. Malfunction of differential gear
- 10 -
5. Malfunction of steering system, wheel and tyre system

6. Warm braw system failure
7. A/C system failure
8. Brake system failure
9. ABS system failure
10. Power system failure
11. Variety of lamps, light system failure, headlight failure
Ⅷ . Disposition of Emergency
1. Starting system not work
2. Instruction of storage battery
3. Overheating of engine
4. Traction of vehicle
- 11 -
Ⅸ. Maintenance of the Vehicle

1. Cleanness of the vehicle inside vinyl plastics
2. Cleanup & Wax of the Vehicle’s Outer Part
.......................................................................
- 12 -
I.Identification of the Vehicle
- 13 -
DENTIFICATION OF THE VEHICLE
1. Identification of Number 2. VIN 3. Serial Number of the Engine

There are two VINs, one is on the The serial number of the Engine
EQ 6 36 0 □□
aluminum plate which is on the right should be marked on the convexity of the
front side of the Meter, and the other is rear lower part of the right cylinder.
A B C D E
on the body which is under the front row
right side seat.
A: Self-Stipulate Code
On the Meter Board
B： Vehicle Catagory Number On the instrument
C： Main Parameter Code
D： Serial Number of the Product
E： Self-Stipulate Code
2) The VIN should be marked on the side

of the frame beam which is under the seat
that beside the driver’s, and above the
Meter Board and on the nameplate.
2
Ⅱ. Main Technical Parameter
3
A. Parameter of Mini Bus

1．Engine Parameters
Refer to the engine specification along with the vehicle
2. Common performance parameter
DFSK MINI BUS/SPECIAL BUS
Items Unit EQ636× EQ638× EQ640× EQ641× EQ639× EQ502×
××series ××series ××series ××series ××series ××series
100，110，115，120， 102，105，
Max Speed Km/h 100，105，120 110，125
125 125
Max Climbing
% ≥30
Capacity
（50km/h）Brake
m ≤20
Distance(full load)
Min Turning
m ≤9 ≤9.8 ≤10.8 ≤9.8 ≤10 ≤9.8
Diameters(m)
4
Main Technical Parameter of the Complete Vehicle
3. Fuel Consumption
DFSK MINI BUS AND SPECIALLY SELECTED ENGINE
Items Unit
EQ474i/EQ474i-30
EQ465i2-30/EQ465i-21/AF10-06/EQ466i-30
BG13-20
Fuel Consumption
L/100
(under limited ≤6.2 ≤6.5
km
condition)
Note：As to the different practical condition, the real fuel consumption will be a little higher than the value
above
4. Main demension
EQ640× EQ641× EQ502×
Items Unit EQ636×× EQ638×× EQ639××
×× ×× ××
×series ×series ×series
series series series
Total Length mm 3640 3795 4040 4070 3905 3795
Total Wide mm 1560 1635 1560
Total Height 2070，
mm 1925 2105 1950
（Empty load） 2160
Wheel Base mm 2360 2515 2760 2515
5
FR. Tread mm 1310 1410 1310
RR. Tread mm 1310 1410 1310
FR Suspension mm 555 570 555
RR. Suspension mm 725 1000 820 725
5. Main Weight Parameters

EQ636 EQ640 EQ639
Items Unit EQ641××× EQ502×××
××× EQ638×××series ××× ×××
series series
series series series
Curb 1000,1015,1020，
kg 985,970 1000,1010,1015,1030 1050 1130,1145,1120 1100
Weight 1030
Total 1605， 1400，1415，1595，
kg 1565 1400，1595，1610 1710 1980
Weight 1800 1610
Seating
Capacity
人 2-8 5-8 5-11 2-8 5-7 2
(Include
Driver)

Items Unit EQ636×× EQ638×× EQ640×× EQ641×× EQ639×× EQ502×
×series ×series ×series ×series ×series ××
6
series
Toe-in mm 0～5
Tire camber 42′±
1°30’ 1°30’
angle 30′
Master pin 9°28′±
( °) 8° 8°
inclination angle 30′
Master pin caster 2°50′±
2°30’ 2°30’
angle 30′

DFSK MINI BUS MODELS
EQ636× EQ638× EQ640× EQ641×
Item Unit EQ639×××
×× ×× ×× ×× EQ502×××Series
Series
Series Series Series Series
Zero 200 200（165/70R14，
kPa 200（165/70R14，155R13LT）
Front load （175/80R14） 155R13LT）
tire Full 200 240（165/70R14，
kPa 240（165/70R14，155R13LT）
load （175/80R14） 155R13LT）
Zero 220 240（165/70R14，
kPa 240（165/70R14，155R13LT）
Rear load （175/80R14） 155R13LT）
tire Full 250 280(165/70R14)，300
kPa 280(165/70R14)，300（155R13LT）
load （175/80R14）（155R13LT）
7
8. Volume Parameters
DFSK MINI BUS AND SPECIALLY SELECTED ENGINE
Item
Unit EQ465i-21/EQ465i2-30
AF10-06 EQ474i/EQ474i-30 BG13-20
EQ466i-30
Cool system of engine L 4.8 5.3
Lubrication system of engine L 3 3.2 4.2 4.2～4.5
Fuel tank L 40，50（Only for EQ6390PF Series）
Lubrication oil of transmission box L 1.2 1.3 1.3 1.3～1.5
Lubrication oil of rear axle L 1.2
Braking oil L 0.6
9.A/C System Parameters

DFSK MINI BUS/ SPECIAL BUS
EQ636 EQ638 EQ640 EQ639 EQ502
Items Unit ×× ×× ×× EQ641××× ×× ××
× × × Series × ×
Series Series Series Series Series
Cooling Ability W 4250 2870 4250
Cooling Wind Speed M3/h 400 300 400
8
Compressor consuption W(Nc2000r/min) 2.13 1.58W(Nc1800r/min) 2.13
Idle
Automatically r/min 950±50（465 engine），900±50（474 engine）
Increase
A/C water
Temperature ℃ 110
Protection
Engine water
Control
Temperature ℃ 90
Parameter
Protection
High Pressure
MPa 3.2
Protection
Low Pressure
MPa 0.2
Protection
Over-heating
℃ 150±5 150±5 150±5
Protection
Note：1. EQ636×××series include：EQ6360LF；

EQ638×××series include：EQ6380LF；
EQ639×××series include： EQ6390PF22Q；
9
EQ502×××series include：EQ5021XXYF。
2. In order to meet the demands of the markets, the newly developed EQ636XXXseries, EQ638XXXseries
and EQ640XXXseries adopt elective materials such as the front bumper bar (including rear bumper bar with
those mini vans converted from mini buses), dashboard, luminaries, side-mirror, decoration boards and seat
fabric. The appearance of the vehicle may not be the same with the specifications listed in this manual.
Please refer to the practical dimension of the vehicle.
10
B. Parameter of Mini Truck
11
1. Engine Parameter
Refer to the engine manual distributed with the vehicle.
2. Common performance parameter
DFSK truck and other special vehicle models
EQ1021NF EQ1021TF × EQ502 × × × × EQ502 × × × EQ502 × × × ×
Item Unit EQ1020TF EQ1021GF24Q7
Truck (Double ×× ×× ××× ××
Truck Truck
cabin) Widened truck Van Van Special truck
Km/
Max Speed 100 100，120 105，125 100，120 100 100，120 100,120
h
Gradeability % ≥30
Braking
distance with
m ≤20
the speed of
50 km/h
Min turning
m ≤9.8，≤10.8 ≤10 ≤9.8 ≤10
diameter
Fuel
L/100
consumption
km
≤6.2，≤6.5 ≤6.8，≤6.5，≤6.2 ≤6.2，≤6.5 ≤6.5
per 100 km
Note: the actual fuel consumption is normally higher than the specification listed in the form.
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3. Fuel Consumption
DFSK TRUCK AND SPECIALLY SELECTED ENGINE
Items Unit
EQ465i2-30/EQ465i-21/AF10-06/EQ466i-30 EQ474i/EQ474i-30BG13-20
Fuel Consumption L/100

≤6.2 ≤6.5
(under limited condition) km
Note：As to the different practical condition, the real fuel consumption will be a little higher than the value above
4. Main Dimension
EQ1021NF EQ1021TF × × EQ502 × × × EQ502×××× EQ502×××× EQ1021GF24Q
Item Unit EQ1020TF
Truck (Double × ××× ×× ×× 7
Truck
cabin) Widened truck Van Van Special truck Truck
4390，4150， 3795，4070， 3795，4150，
Length mm 3980，4160, 4410 4538 4335，4220，4150 4280
3980， 4040 4185，4220
Width mm 1560 1635 1560
Height (zero
mm 1825 1860 1890 1925，2105 2150 2160，2490 1850
load)
13
Wheelbase mm 2515，2760 2515，2760 2760 2515 2760
Front tread mm 1310 1415 1310
Rear Tread mm 1310 1410 1310
555/1080
Front 555/725，
， 555/910， 555/725， 555/1265
suspension/ 555/1080，
mm 555/1075 555/1090, 570/1208 555/1000， 555/1150 580
Rear 555/1115，
，555/880 555/1095 555/1000 555/1080
suspension 555/1150
2700，
内尺寸 2460， 2460，2370，1650 1650，2310，2460
1390，1650, 1900， 2800×1540×
Inner size of mm 2290× —— ×1440，1430， ×1330，1400， 940
×1440× 340,430 350
carriage 1440， 1400×1350 1440×340，430
340
5. Main weight parameter
Item Unit
EQ1020TF EQ1021NF EQ1021TF××× EQ1021GF24Q7
Truck Truck with double cabin Widened truck Truck
Curb weight Kg 910，900，880 965，1030 990 970
Total weight kg 1810，1530 1780 ，1845 1920 1700
Passenger
capacity/ 2/790,2/800
人/kg 2+3/490 ，2+3/490 2/800 2/600
Loading 2/490
capacity
14
6. Wheel Alignment parameter
Item Unit EQ1020TF EQ1021NF EQ1021TF××× EQ1021GF24Q7
Truck Truck with double cabin Widened truck Truck
Toe-in mm 0～5
Tire camber
1°30’ 42′±30′ 1°30’
angle
Master pin
inclination （°） 8 9°28′±30′ 8
angle
Master pin
2°30’ 2°50′±30′ 2°30’
caster angle
7. Tire air pressure

Item Unit EQ1020T EQ1021NF EQ1021TF × × EQ502 × × EQ502 × × EQ502 × ×
EQ1021GF24Q7
F Truck (Double × ×××× ×××× ××××
Truck
Truck cabin) Widened truck Van Van Special truck
Zero 180（165/70R14）
kPa 200（165/70R14，155R13LT） 200（185R14LT） 200（165/70R14，155R13LT）
Front load 200（165R13LT，155R13LT）
tire Full 220（165/70R14）
kPa 240（165/70R14，155R13LT） 220（185R14LT） 240（165/70R14，155R13LT）
load 240（165R13LT，155R13LT）
Zero 200（165/70R14）
kPa 240（165/70R14，155R13LT） 220（185R14LT） 240（165/70R14，155R13LT）
load 220（165R13LT，155R13LT）
Rear
250（165/70R14）
，
tire Full 280（165/70R14）
，300
kPa 240（185R14LT） 280（165/70R14）
，300（155R13LT） 300（165R13LT），
load （155R13LT）
375（155R13LT）
15
8. Volume parameter
Item Elective engines for DFSK truck and special truck models
Unit
EQ465i2-30/EQ465i-21 AF10-06 EQ474i-30/EQ474i BG13-20
Cool system of
L 4.8 5.3
engine
Lubrication
L 3 3.2 4.2 4.2～4.5
system of engine
Fuel tank L 40
Lubrication oil of
L 1.2 1.3 1.3 1.3～1.5
transmission box
Lubrication oil of
L 1.2
rear axle
Braking oil L 0.6
Note: 1. EQ1020TF truck series includes: EQ1020TF 2.3M,2.5M,2.7M；

EQ1021NF double cabin truck series includes: EQ1021NF 1.4M 1.7M 2.0M
EQ1021TF widened truck series includes: EQ1021TF22QN11 2.9M
EQ1021GF24Q7 Truck series includes: EQ1021GF24Q7 2.3,2.5M
EQ502×××××× van series includes: EQ5021XXYF,EQ5024XXYF4, truck with aluminium alloy carriage, refrigerator truck,
dumper truck, vender truck
2. In order to meet the demands of the markets, the newly developed truck series adopts elective materials such as the front bumper bar
(including rear bumper bar with those mini vans converted from mini buses), dashboard, luminaires, side-mirror, decoration boards and seat
fabric. The appearance of the vehicle may not be the same with the specifications listed in this manual. Please refer to the practical dimension of
the vehicle.
16
Ⅲ、Vehicle Devices & Mechanics Operation
17
1. Door While locking the front and back door

Open without key outside the vehicles, the
locking buttion shall be pressed down
Lock while the door is open, and pull up the
window, then close the door.
Note：
The door shall be locked well,
and the locking button shall be pressed . This vehicle is with two keys,
Inside the Vehicle： down while driving to avoid any please keep one in a safe place for
unexpected open of the door. spare use.The other can be used for
All the doors can be locked by
ignition switch, front door and back
pressing down the locked button. After Back door： door.
that, the door can not be open either Please keep the key along with you
While locking the back door, the
at any time.
inside or outside the vehicle. When back door shall be closed first and
3. Front Door Window
open it, pull the locked button upward. then turn the key clockwisedly. While
Front Door： open the door, turn the key
The front door can be open and locked counter-clockwisedly and open the
by key. The locking button rises while door.
open, and is down while locked. 2. Key
Back Door：
The door windows of front door are of
The locking button rises while two types, manual and electric.
open, and is down while locked. When by hand, there is handlebar
10
on the inner side of the door. Turn the
handlebar clockwise or
counter-clockwise, the door window
will come up or come down.
4. Front Door
Press down the button 4, then button 3

The windows of rear doors are
can not work, press again, then the
controlled by the inner handle, the
button 3 is workable.
window will be close or open while
turn the handle clockwisedly or
There is a lift switch inside the door
counter-clockwaisedly.
while using the electric mechanism for
6. Seat
the window.
Switch 1 for the driver to control the
window in the side of the
co-pilot.
Switch 2 is for use of the window in Pull up the button, the window will be
the driver’s side. closed; press down the button, the
Front Row Seat
Switch 3 is for use of the window in window will be open.
the co-pilot’s side. 5. Rear Door window The fixing of the front row seat is
just like the picture below, make the
11
two pothooks hook the button, and
then fasten it. It is for three passengers, while folded the
Adjustment of the Front Row extra one, pull outward the backrest locking
Seats: device and fold the backrest horizonally,
Pull up the movable adjustable handle, then pull forward the outward handle under
and the seat can be moved to a certain the seat, fold the seat well and make it close
place as required; pull up the backrest to the middle-row seat.
handle beside the seat, the backrest
can be moved freely, loose the hanlse,
the backrest will be locked and the Middle-row seat：
backrest can also be folded forward.
The middle row seat has two kinds:
moveable and folding.
Movable Seat
Pull up the adjustor of the sliding rail,
and the seat can moved freely forward
or backward, while the seat moves to a Rear Row Seat
Note：: suitable place, loose the adjustor, then
No adjustment to the seat is There is a stopper for the rear
allowed during the driving, or else, the the seat will be locked.
row seat, pull out the stopper, and
seat may move abruptly forward or Folding Seat
backward which may cause the backrest can be put horizonally, after
driving out of control. than, loose the stopper handle; while
open, turn the backrest to the final
position, the stopped will be locked
12
automatically. requirements.While undo the safety
belt; press the release button on the
lock catch.
The customers should not do any
amendments; otherwise it may cause
the safety belt not being adjusted
which will influence elasticity.
座椅锁闩
Note:
Pls wear the belt while driving.
7. Safety Belt
The safety belt of the front row seat is
automatic contraction.While using,
please pull out the lock tongue which
connect the safety belt and wing your
Turnover of the seat：
body and pass, then push the lock
There is a latch for the rear row tongue to the lock catch until hear the
seat, turn on the latch, the seat can be “clatter” sound.
The length adjustment of the saftety
turned over 90° forwardly so as to belt is very important. While adjusting
As low as buttock
loading or discharging goods. The the lap belt, please check the lock at
the meantime to make sure that it has
latch shall be guaranteed to be locked been locked, and then pull up the
while the seat returns to its original shoulder belt till the lap belt being
buckled tightly. The length of the
place. safety belt can be adjusted freely
according to different
The safety belt is designed according
13
to the human body skeleton, (See the Safety belt should be prevented from Do not use the deformed saferty belt.
picture). Please note that, the waise polishing compound, grease spot, chemical One safety belt is only for one person,
band part shall not be across the article, especially storage battery sour liquid tie the children on knee of passenger
polluted. While washing, you can use
abdomen. neutral soap and water. If the safety belt is
to the safety bealt is very dangerous.
The adjustment of the safety belt is not worn and torn, polluted or damaged, should The position of lock limit position
only reliable and comfortable but also be changed. should not interfere or block the safety
can help to make safer. Flexible safety It is very important that when the safety belt belt fully withdraw.
belt will influence its protection impacted fiercely, though it is not obvious,
function. it should be changed.
14
8. Dashboard 1○4 Emergency Switch 9、Side Intake

①Assembled Meter 8. Dashboard（One and half of cabin） 10、Centre Intake
②Ignition Switch 11、A/C Switch
③Lighting/Turning and high/low 12、Switch Assy Defroster
beam converting switch 13、Rear For Switch
④Wiper & Syringe Switch 14、Fog Switch
⑤Cover for Optional Switch 15、mergency Switch
⑥Other Switches
16、Tool Box
⑦Control Board for Heating
17、Control Board for Heating
⑧Cigar Lighter 1、Assembled Meter
18、Ignition Switch
⑨Cigarette Ash Box 2、Wiper & Syringe Switch
⑩Switch for front cover board. 3、Lighting/Turning and high/low beam 9. Fire Switch
1○1 Centre Intake converting switch
1○2 Side Intake 1. ‘Off’: the auxiliary equipments don’t
4、Head lamp control switch
work, only head lamp and horn work,
1○3 Tool Box
5、Rear Foglam and the key can be pull out only in this
6、Rear Foglam position.
2. ‘ACC’: assisitant equipments
7、Cigarette Lighter (radio & cigar lighter) work and the
8、Auxiliary Frame Air Bag engine don’t work.
3. ‘On’: while at this position, all
15
the wiring can be put through and the

engine prepares to run.
4. ‘Start’： On this position, the
engine is started by the starter, once the
engine starts. Please loose the key
which will return to ‘on’automatically.
Do not keep the ignition key
in’ON’position for a long time unless
the engine is running, or else, the
battery will discharge.
Note: The working time for starter The control pole is in the left side
shall not exceed 5 seconds. If the
engine cannot be started, please wait of the steering pole, the operation is as
at least five to ten seconds, and try follows:
again. If the engine fail to start after
several times, please check the fuel
power supply system or pay a visit to
the Maintanence Stop of Dongfeng
Yuan Vehicle.
10. Lighting, Turning and
High/Low Beam Control Pole
16
control pole be loosen, when there is no

lotion but turn on thecontrol pole will
lead damage to the generator. If
attempting to clean the dash by wiper
will lead damage to the wiper and glass.
The first step should be the wet of glass
then start the wiper.
There are four gears Note:

Press down the button, all the four When it frozeon the glass should
INT：Intermission gear, whichis the ice and snow be cleaned first and
turning lights and the side turning lights connect to the defost device, then start
used when foggy and sprinkle
glitter simultaneously. Press the other the wiper.
days.
end will turn off the lights. 12. Rear wind window wiper
LO：Run in a low but stable speed.
This switch is only used for emergency and cleaner switch
situation and running in abnormal HIGH：Run in a high but stable
situation. speed.
11. wiper and cleaner control
OFF：Stop gear.
lever
Pull the control pole back
will lead to spray clean lotion.
Note:
When the lotion stops should the Rear wind window
17
No cleaner and single-arm

wiper installed to rear wind
window.
Press the wiper switch (on
the dash board) one time, the rear
wind window wiper starts to
work.
Press the wiper switch
another time, the rear wind
window wiper stops.
13. Horn
The horn is going to roar
whenever the horn button is
pressed wherever the ignition
switch is.
18
Press down the button, all the four

The horn button is on the wheel Press the emergency light, all the turning lights and the side turning
panel lights glitter simultaneously. Press the
four turning lights and sideway other end will turn off the lights.
① if it is a TOM’ style wheel turning lights will flash at the This switch is only used for
emergency situation and running in
panel, the wheel should be at the same time. And press the other abnormal situation.
middle of the panel. side of the button will stop this. 15. Foglight Switch：
②if it is four-classified panel, When the vehicle is in an
the horn should be at the both emergency or abnormal
sides of straight range . condition, use this switch.
14. Emergency light switch
Front Foglight:
Turn the headlight switch to the
19
second gear, and press the foglight the indicator light.
Rear Foglight
switch, the foglight will be turned on, Turn the headlight switch to the
and so will the indicator light; press second gear, and press the foglight
switch, the foglight will be turned on,
again, the foglight is turned off, so is
and so will the indicator light; press
the indicator light. again, the foglight is turned off, so is
16. Heating System:

The heating system is for heating, defrosting and ventilation.
①Defrost Exhaust Valve of Windshield

②Centre Exhaust Port
③Side Defrost Exhaust Port
④Exhaust Port of the Floor
16. Heating System（One and half cabin）
20
Vehicle Devicesxs and Mechanics Operation
①Windshield defrosting air door

②The central vent hole
③The side defrost vent hole
④The broad vent hole
21
17.Control Board of Heating the defrost exthaust port of windscreen gas vent.
System and side defrost exhaust port. Note:
The time for blowing should not be
⑤ Defrost
too long while the air is in inner
⑥ Cycle Control Button of Inside circulation so as to avoid the air in the
& Outside vehicle too dirty and the windpane
will become humidity and with low
Control the circulation of the air of thickness oxygen.
① The wind is sent off through inside & outside. 17.
the intake in the centre of the the ⑦ Tempreture control button Control Board of Heating
meter board or through side Control the tempreture of cold & System（one and half cabin）
warm air (blue is cold air, and red is
ventilation. warm air)
② Sending off wind in both ⑧ Draft Control Button
directions: Cold air is sent off from the Control the rotate speed of fan, that is,
centre intake, and the warm air is sent adjust the draft.
off from the bottom intake. ⑨ Optional Button for Ventilate
③ Warm Air Position ① The wind is sent off through
Warm air is sent off from the exhaust
This button can choose the warm air the intake in the centre of the
port on the floor.
④ Defrost & Warm Air form from the aforesaid ①—⑤ gas the meter board or through side
Warm air is sent off from the exhaust vent. This button can choose the warm ventilation.
port on the floor, some is sent off from air form from the aforesaid ①—⑤ ② Sending off Wind in both
22
directions: Cold air is sent off from the windscreen and side defrost exhaust Control the rotate speed of fan, that is ,
adjust the draft.
centre intake, and the warm air is sent port.
⑨ Optional Button for
off from the bottom intake. ⑤ Defrost
Ventilate Position
③ Warm Air ⑥ Cycle Control Button of Note:
Warm air is sent off from the Inside & Outside The time for blowing should not
Control the circulation of the air of be too long while the air is in inner
exhaust port on the floor. circulation so as to avoid the air in the
inside & outside.
④ Defrost & Warm Air vehicle too dirty and the windpane
⑦ Tempreture control button will become humidity and with low
Warm air is sent off from the Control the tempreture of cold & thickness oxygen.
exhaust port on the floor, some is sent warm air (blue is cold air, and red is
warm air)
off from the defrost exthaust port of
⑧ Draft Control Button
③ Left & Right turning indicator
light
④ Water Thermometer
⑤ Fuel Gauge
⑥ Short-range Odometer
⑦ Return Button for Short-Range
This is just for reference
Odometer
① Speedometer
18. Assembled Meter ② Odometer
23
18.
Assembled Meter（One and half The speedometer expresses with km/h
cabin） the speed of the automobile.
Odometer
The odometer has six -figure number

① Speedometer in all to show the total driving mileage,
② Short-range Odometer the minimum unit of mileage is 1km.
The picture is just for reference） Odometer after finishing caculation ,
③ Left & Right turning indicator
light ① Speedometer count again since " 0 " , analogize
④ Fuel Gauge sequentially to count for the first time.
② Left & Right turning indicator
⑤ Water Thermometer Note:
light Pay attention to the running
⑥ Accumulative total odometer mileage, and maintain the vehicle
③ Fuel Gauge
⑦ Return Button for Short-Range according to this instruction manual..
Odometer ④ Return Button for Odomet
⑧ Tachometer ⑤ indicating instrument Water Thermometer
⑥ Water Thermometer
⑦ Function Indicator Light
Speedometer
24
While driving, the water

While the pointer at the
tempreture should be kept in the
‘F’position, it shows that the fuel tank
normal scope, that is: between ‘C’&
is full of fuel; while at the position of
‘H’. When the pointer moves to
‘E’, it shows the fuel tank is empty
‘H’direction and exceeds the scope, it
means the engine too hot, you should
stop the vehicle.
Fuel Gauge
25
18. in all to show the total driving mileage,
the minimum unit of mileage is 1km.
Assembled Meter Odometer after finishing caculation ,
count again since " 0 " , analogize
sequentially to count for the first time.
The short odometer has four figures to
show the speed.
18. Assembled Meter
In the short range of milage, the last
figure means the figure behind the
decimal, the minimum unit of mileage
is 0. 1km, the return button can return
图1 the mileage of short distance of
odometer to " 0 " mileage.
Note:
Pay attention to the running mileage,
and maintain the vehicle according to
this instruction manual.
图2
The speedometer expresses with km/h
the speed of the automobile.
The odometer has six -figure number
26
18. Assembled Meter ‘H’. When the pointer moves to
‘H’direction and exceeds the scope, it
means the engine too hot, you should
stop the vehicle.
18. Assembled Meter
While the pointer at the ‘F’position, it

Chart 1 shows that the fuel tank is full of fuel;
while at the position of ‘E’, it shows
the fuel tank is empty.
18. Assembled Meter
When the ignition switch is on the

position of turn-on, making the
Chart 2 turning switch gets through, the
indicator light will flicker and the
Tachometer turning light turns on showing turning
Show the rev of engine with signal given. Turning left, the left
1 unit as 1000rpm. indicator light turns on; turning right,
While driving, the water the right indicator light turns on.
18. Assembled Meter
tempreture should be kept in the
normal scope, that is: between ‘C’&
18. Assembled Meter
27
18. Assembled Meter
When every headlight adopts high

When ignition switch puts through,
beam or dipped headlight, this When putting ignition switch through, this indicator lamp lights immediately,
indicator light will be on. this indicator lamp lights immediately, and engine goes out immediately after
18. Assembled Meter after the engine is started, it will go starting. Otherwise it shows the
out immediately. Otherwise it shows battery charge system breaking down,
the oil level of the bottom shell of the please check if the fan belt ruptures or
engine passes low or the lubricating relaxes at first, if normal, carry on
system breaks down, please make the circuit check again or get in
engine go out and carry on the oil touch.with the distributor or Dongfeng
level check and annotate immediately. YUAN Maintenance Department.
If fail to fix a breakdown yet, please
While confronting emergency, please go on an all-round way checking of
lubricating system or get in touch.with
use the emergency light, the indicator the local distributors or Dongfeng
light flickers so as to avoid hitting the YUAN Maintenance Department.
behind vehicles. 18. Assembled Meter
Note:
This switch can be only used
when meeting emergency.
28
18. Assembled Meter Note
It shows the brake system Note:
breaks down when the ignition At this situation, it
switch is on the position of necessary to need longer
‘ON’or ‘START’ but the parking distance, more powerful
indicator light is not on or it is pedal force and longer pedal
not out after the engine starts or stroke.
the indicator puts through
abnormally while driving. If on
these cases, please ask the
In normal cases, when the ignition Dongfeng YUAN Maintenance
Department for help.
switch in ‘ON’ or " START " When the indicator light puts through
position, the light is on , and it will go abnormally, please bear the vehicle off
out after the engine starts.when the the road and test the brake system on
liquid level of the container of brake the roadside.
liquid is lower than the fixed liquid After test, please drive the vehicle to
the nearest maintenance stop at low
level, the light will be on. And it will When the ignition switch puts through,
speed if you believe it is safe for do so.
be out after adding brake liquid this indicator light will be on and will
Otherwise please trailer it to the
be out after the safety button inserting
according to the regulation. maintenance stop.
into the safety belt fixing housing
18. Assembled Meter which shows the safety belt has been
well buttoned.
18. Assembled Meter
29
indicator lamp will go out, if the position.
trouble indicator lamp does not go out 20. Cigarette Ash Box
while the vehicle starts or lights in the
course of running, it shows the engine
control module breaks down , please
While the ignition switch is in the ask Dongfeng YUAN Maintainer for
position of put-through and the help.
parking brake is in the condition of The ash box can be used after being
unreleased, the parking brake light 19. Cigar Lighter pulled out, while clearing up the
will be on. cigarette ash, push it downwards, then
18. Assembled Meter totally pull out from the socket
outwards. Push the ash box along the
guide while putting.
Note:
The cigarette end should be
put into the ash box after
putting it out so as not to
cause fire.
Press the cigarette lighter button, wait
When the ignition switch is in the 20. Cigarette Ash Box
position of ‘ON’, the trouble lamp will several seconds and the resistance
be on, it shows the the trouble lamp wire will turn red and hot, and it can
circuit is normal.
be taken out to use after it
After the engine is started, the trouble
automatically rebounds to its original
30
（12）USB
Put the cigarette end into the ash box
after going out. While clearing up,
press the ash box spring down, you 22. Tool Box
can pull out the box. Hold the ash box 1. Electric Source Switch & Volume
vertically and insert it to the groove
until clenching the teeth of the trough. 2. Advance/Back Key
21. Stereo Radio 3. Wave Band Tuning Knob
4. Balance Control Knob
（The picture is just for reference）
5. Tone Control Button
（1）MUTE
6. Hour Setting Key
（The picture is just for reference）（2）On-Off/ Sound Effect Knob 7. Minute Setting Key
1 Electric Source Switch & Volume ( 3 ) umber Button 22. Tool Box
2 Forward/Back Key (4) Lock Set Button
3 Wave Band Tuning Knobs ( 5 ) FM Button
4 Balance Control Knobs ( 6 ) AM Button
5 Tune Control Button （7）SET Button
6 Hour Setting Key ( 8 ) USB Button
7 Minute Setting Key （9）AUX Button 23. Inner Light & Interior
21. MP3& Radio （ One and （10）AS/PS Knob Rear View Mirror
half of cabin）（11）AUX
31
The indoor light button consists of Regard the inner mirror and inner rear
three pieces of shelf location. view mirror as a combination and it is
“OFF" is closed. set up in the middle of the top of wind
“DOOR “means switch at the door, window.
When the button is in this shelf, the Inner view mirror can rotate from side
light is off while closing the door and to side up and down along central axle;
the light is on while opening the door. and park it at the any position inside.
The indoor light button consists of
As any door is closed uncompletely, 23. Inner Light & Interior three pieces of shelf location.
this light will not go out. Rear View Mirror “OFF" is closed.
“ON” means being turned on, while
the button is at this shelf, the inside “DOOR “means switch at the door,
light will be on. when the button is in this shelf, the
23. Inner Light & Interior
light is not on while closing the door,
Rear View Mirror and the light is on while opening the
door. As any door is closed
uncompletely, this light will not go
out.
“ON” means being turned on, while at
this shelf, the inside light will be on.
32
24. Interior Top Lamp that you can see the behind vehicles or
other objects through it. And the Safe handgrip is located on the upper side
surface of the outer rear-view mirror is of each seat (The driver’s side doesn’t
protruding surface. have.)
While judging by the vehicle or other
objects through the protruding lens, Note:
please pay attention that the articles will While in the course of running, the
be much smaller and farther than seeing passenger should hold the handgrip
through the flat mirror.
tightly.
The interior top lamp is set between
the top of middle row and rear row of
26. Sunshading Board Do not hang anything on the handgrip
The sunshading board can rotate up to prevent it from influencing the
seats, with two shift position. and down by winding its pivot. While driver’s line of sight which may cause
ON means open; Put thebutton in the adjusting, place hands close to both accident.
ends of the mount ing pad and rotate.
position, the lamp is on. 28. Tool Kit
OFF means close, put the buton in the There is a small mirror on the back of
sunshading board which is on one side
position, the lamp is off. of co-pilot.
25. Outside Rear View 27. Safe Handgrip
Mirror
Adjust the outer rear-view mirror

according to your demands making
33
① Tool Bag
② Plier
③ Hatch Spanner12×14
○
4 Screwdriver
○
5 Handlebar of Screwdriver Draw up the brake rod, the vehicle
○
6 Handlebar of Sleeve Clutch Pedal
will stop; when release the stopping Clutch pedal can break transmission of
○
7 Sleeve for Spark Plug
brake, pull the brake rod a little up and engine and wheel. Step down the
○
8 Spanner for Tyre footboard, the engine power
○
9 Crank of Jack push the button on the top of the brake
disconnects, loose footboard, power
10
○ Jack rod with thumb and then put back the recover.
11
○ Triangle Warning Plate brake rod in the normal position.
The tools shown in the picture are one
for each, and Note:
Parking brake rod should be drawn up
②③④⑤⑥⑦⑧⑨⑩ should be
totally, otherwise it is unable to
put in tool bag ①. Please refer to
prevent wheel from rotating, when Brake Pedal：
Chapter 5 ‘Instruction for using Jack’
parking in the extremely cold weather, al condition such as cold, humidity,
to check the placement of the jack and
please put the shelf in the low-grade or ice and snow etc. will cause the brake
jack crank.
reverse grade, live in the wheel with shriek, it is normal, if the brake
cushion headblock. screams in every brake or shrieks
29. Brake Rod by hand 30. Pedal loudly, please check the brake system.
Accelerator Pedal：
The rotating speed is controlled by
accelerator pedal, step down the
34
accelerator pedal, the rotating speed of Reverse gear: pull towards left
the engine will increase and the output 32. Front Storehouse Cover
power will go up.
31. Shift Handlebar
1st gear: first pull towards to left and The handle of front storehouse lies
then push forward. below left of the instrument board of
2nd gear: first pull towards to left and the driver's cabin. Before opening,
then pull backward please pull the handle outwards and
3rd gear: push forwards in the central then the handle up to open the front
position cover, then prop up storehouse cover
Note: 4th gear: push backwards in the central with struts.
Do not change the gearlever position
from 5th gear into reverse gear. 5th gear: pull towards right first and
Please first push the gearlever to then push backward
neutral and then change into
reverse gear.
35
Ⅳ、Operation of the Vehicle
36
1.Running-in The first

In the course of car running-in, we use Gear 2500
Note:
the best material, every part is kilometers
Once the engine starts, please
processed meticulously, but before the Max Gear 1 15Km/h release the ignition key to disconnect
letting the engine bear peak load, each Recommended
Gear 2 25Km/h the starter, otherwise, it may cause the
operating should pass running-in stage. Speed
Gear 3 40Km/h starting system to be damaged. Do not
The initial maintenance and try to sart the engine once for more
running-in of the engine have close Gear 4 60Km/h than five seconds, if it fails to start,
relationship with its future Gear 5 75Km/h please try again ten seconds later (let
performance and dependability quality, the battery supplement electricity).
the general principle that should be 2. Start of the Engine
After the cold engine is started, don't
followed is as follows: Before the Start of Engine make the engine run idle at a high
1. The running-in mileage is 2500KM. Make sure the brake has been speed.
2. Do not exceed the running-in speed locked up. 3. Safety Driving
limit value listed in the table below. Make sure the joy stick of the derailler
3. While in the course of running-in, is in the position of neutral. Start the Engine
the loading born shall be lessen than ①While turning the ignition switch
400kg. to “START ", you can start the engine.
4. After starting, do not make the Note: The electric jet system can offer
engine run idle at high speed, please Before starting the engine, hold suitable blending gas mixed by oil and
pre-heating the engine. the hand brake to lock up the gas and ignition advance angle, so it is
wheel and the gearlever should be unnecessary to step on the throttle
in the position of neutral. 37
Guide for Vehicle Operation
under any circumstance.. after starting, the curb idling will be parking at the slope which may
②If you can't start engine while damage the clutch.
normal, and then repeat the above
trying several times, the engine might While driving the vehicle, drivers
course. Please check at first
happen with “flood the jar “which should frequently observe the
whether there are vehicles coming instrument and indicator lamp, and do
cause the short circuit of the spark not step on the gas before the engine
here and then step on the clutch to do not reach normal working
plug. On this situation, please
have a try, then put into the low-gear, temperature (80 degrees Centigrade -
completely step down the throttle 90 degrees Centigrade), otherwise will
if it is difficult, please step on the shorten the life-span of the engine and
pedal and try again to start the engine
clutch to try again, after putting to hinder changing the gear steadily. The
(then the ECU will control fuel drive is along with synchronization
injector cutting off oil supply). Five gear, let go of brake pole, meanwhile, test machine which make the gearshift
step on throttle slowly, when step on easy and without noise. A good
seconds later, the high-speed air
gearshift would enable rotational
current blow down the overflow oil the clutch, listen to the voice of the speed of the engine remain throughout
and then let go of gas pedal and can engine, with the gradual release of the in a certain range, and no matter how
the speed change, you can both save
restart the engine at this moment. clutch, the engine voice will the fuel and lengthen the life-span.
③If ECU has been cut out (such as change,then step on throttle and let go 4. Brake
The braking distance of the vehicle
change the battery, ECU, and ECU of clutch pedal gradually. increases with that of the speed of
will not power off while parking), 3. Safety Driving vehicle, while applying the brake, you
should guarantee that there is enough
when starting, please turn the key to " When driving the vehicle, don't distance for the vehicle to get to the
ON ", if failed, please wait for five to regard the footboard as a stop for a brake parking point in order to
decelerate gradually.
ten seconds or wait fifteen seconds rest, or don't half step on clutch while
Step on down brake pedal, the front
38
and rear brake will work at the same lower the fuel consumption:
time. If there are shrieks some times
while braking, it is because of ①Avoid running idle for a long time:
humidity of the road surface or cold If you don’t drive the vehicle after
and snow weather etc. So it is a
normal. waiting more than one minute, you
should stop running the engine. While
starting the cold engine, you should
operate idly until the indicator of the
Note: thermometer reaches “C " position ,
If there are always shrieks when then begin to drive a vehicle.
brakes, please go to the Service The vehicle is equipped with vacuum
Station of Dongfeng YUAN. ②Avoid Emergency Brake: it is a
helping system; it can make the brake
Don't apply the brake in succession more stable. Do not step on the brake waste of energy for braking and also
for a long time, or put the foot on pedal to-and-fro while applying the
the brake pedal while running for a recovering driving speed will consume
brake. When the vacuum helping
rest which will cause the brake to system lose efficiency, the energy the fuel.
lose efficiency for overheating or
the braking distance too long or
stored will gradually subside effort in ③Keep the invariable speed: Keep
brake pedal with applying the brake
will cause the permanent damage each time. the invariable speed in the allowed
of the brake.
road and traffic condition.
Note:
5.Without
Economy Driving
the vacuum helping system,& ④Keep the loading capacity
Note:
After water enters the brake drum, it
Environmental
it will need more Adaptability
footboard strength minimum limi
while applying
Economy Driving:the brake and
will make the brake lose efficiency or perhaps the braking distance will be ⑤Keep the correct tire pressure:
its performance cannot be predicable. The following items will help you to
longer.
So after the vehicle paddles or being when the tire pressure is insufficiency,
washed, you should lightly step on the 39
brake pedal intermissively at a much
low speed, operate the brake
the resistance for driving will increase Driving on the icy road low gear promptly according to the
You can use the tire tyre chain in slope and the rotational speed of
which may cause the waste of the fuel, order to prevent the tire sliding on the engine in case that the engine
then the tire should be pumped icy road. overloads or being damaged. Pay
Step on the brake pedal repeatedly and attention to following points while
according to the pressure indicated on steadily and evenly while applying the driving on the ramp:
the plate of the the driver’s side door. brake, instead of stepping on the brake ①The vehicle should be changed into
pedal suddenly so as to achieve ABS.
Start, accelerate or when driving a low gear while climbing the slope in
vehicle, please keep invariable speed order to increase the engine torsion.
to prevent wheel from turning round Gearshift should be fast in case that
Note: and round or skidding which may the engine stops working;
Please don't slide with neutral cause the vehicle sideslip.
when going, because vehicles with Avoid the operation of the steering ① Vehicle should be put into
electric jet system have the function of wheelby turning fast or at large angle. low-gear at the downhill path, try to
gearing down and cutting off oil Decrease to the safe speed and slowly
supply which can guarantee the change direction. brake the vehicle by taking advantage
economy driving. And the engine If increasing the friction by equipping of engine.
keeps working at idle speed while with tyre chain, please pay attention to
running with neutral; it will still ② Try not to make the rotational
following points:
consume the fuel instead of saving Assemble the vehicle according to the speed very high.
fuel. Instruction Manual of the
manufacturer. Note:
The speed should be limited below Do not step down the brake
50KM/H while driving with tyre pedal for too long time or step the
chain. brake pedal for many times while in
5. Economy Driving & Driving on the ramp (road of the course of abrupt slope long
mountain area) slope, which will cause the brake to
Environmental Adaptability While climbing, change the gear to a lose its braking ability for being
overheated. 40
41
Ⅴ. Guide for Vehicle Operation
42
1.Fuel damaged, and method of adjusting and about 6-9mm and assure there is no
changing of the belt are as follows:
1. Unclamp the three setscrews of the any damage to the belt. If the belt
generator. needs replacement or adjustment, pls
2. While wanting to stretch the strap,
unscrew and draw outwards the go to the authorized service center of
generator, fix the generator when the DFM mini auto for maintenance.
strength of the belt reaches
4. Engine Oil
above-mentioned criterion.
3. While changing the strap, unscrew Engine Oil Trademark
The oil shall be No. 93 high-quality and make the generator slip and move Use 15W/40SP while the tempreture is
unleaded gas. The capacity of fuel inwards, Tighten the strap according above 15°in summer; and use
tank of this vehicle is 40 liters; Refuel to the regulation of 2 after changing 10W/30SF (GB11121) while the
access cap lies in the right below part the strap. tempreture is below 15°in winter.
of center pillar. Open up the the cover
by key and turn counterclockwise, and 3. Compressor Belt Note:
then turn the key clockwise to cover it Change the
Measurement and engine
changeoil while the
of engine oil,
tightly. running-in of the new
engine oil of level see DELPHI gasoline
2. Generator Strap vehicleor is
system unite2500KM
electricityand after
systematic
normal driving
electricjet serial for 5000KM.
petrol machine use
While exerting the strength of about and maintain the manual.
98 Newton (strength of 10 kilograms)
to the adhesive tape of the fan between
The vehicle with A/C is
4. Engine Oil
the generator and fan, the down
quantity of new fan adhesive tape is equipped with compressor. During
about 7-10 mm and the down quantity
inspection, press the belt by the thumb
of old fan adhesive tape is 10-15mm.
In addition, check whether the belt is with the regulated power, it will sink
43
Check/Maintenance Service
petrol machine use and maintain the
5. Engine Belt manual.
7. Thermostat
Note: Note:
In order to make oil filter fasten It is dangerous to
properlr, the more important thing discharge the radiator cover
is to mark the position while the while the temperature of the
small filter rubber washer meets water is very high, because the
the installing surface and the oil boiled water and steam will be
filter should not be screwed too
Replacement of the Engine Oil sprayed out under pressure. It
tightly, if the engine oil leaks from is allowable to discharge the
While changing the engine oil filter, the filter rubber washer, that radiator cover when the
unscrew the engine oil strain; Remove shows the filter is fixed unproperly temperature of the coolant is
the engine oil filter by turning or the washer cover is damaged. low.
counterclockwise, the clean the engine
6. Coolant Trademark 8. Transmission Oil
installation surface with a clean cloth; Gear oil of 85W/90 GL-5
Adopt the glycol water antifreeze.
Spread some engine oil around the Refer to the service maintainance
rubber washer of the engine oil strain Note: instruction manual of the gaslion
The vehicles must be parking on machine of DELPHI system or unite
and twist to new oil strain with hand i electricity systematic electricjet serial
the plane ground while changing
until the oil strains rubbers reach to the coolant. petrol machine use and maintain the
the installing surface.And then twist manual.
Add, change and infuse coolant
the strain engine oil to 3/4 of the Refer to the service maintainance
9. Gasoline Filter&Oil
circles by strain spanners. instruction manual of the gaslion Supply Tube& Oil Return
machine of DELPHI system or unite Tube
electricity systematic electricjet serial
44
There is 0.3MPa in the oil supply

The filter element of the air cleaner
system. While changing gasoline filter and The spark plug is F6TC (4C7T) and
should be often removed and washed.
oil supply tube and oil return tube and tie-in, Wash once when running 10000KM the whorl is M14 *1. 25.
you should adopt the right fittings from on the pitch road, wash once each time
while running 2500 kilometers at dirt When there is accumulated charcoal in
Dongfeng YUAN. You had better go to the plug, it is difficult to produce
road.
Dongfeng YUAN AUTO maintainance electric spark. Remove the charcoal
station, otherwise may leave your car in Refer to the service maintainance
with the wire or the needle, and adjust
hidden danger.
instruction manual of the electric jet
series engine of DELPHI system or the spark plug interval to 1. 0-1. 2mm.
Note: unite electricity system for the The interval should be even and the
While replacing the above dismantlement, clearance and fixing of same on the electrode level of the
fittings, please pay attention to the Air Cleaner.
whole centre.
avoiding fire caused by fuel jet. 11. Spark Plug
10. Air Cleaner The spark plug whose pitch of screw
is incorrect in size is not to be used.
If the whorl is stretched out or
indentation while covering, it will
45
gather the charcoal powder in the
exposed whorl part. In this way, when
Note:
Every performance index of air
throttle has been adjusted qualifiedly
According to the situation of the already when the engine is dispatched
imported vehicles euipped with from the factory. The user is not
gaoline spray system used in China allowed to adjust the adjusting screw
dismantle the spark plug or change
and the actual conditions of and petrol of the throttle by himself, otherwise it
with the correct spark plugging will product which our country use at will effect the correctness of the data
Note:
cause the damage
While installingofthe
thespark
whorl.
plug, please present, the vehicle, while parking for of the sensor located in air throttle and
exert to screw it to prevent damage to the a long time, should start the engine then effect the performance and
whorl, then screw it tightly by spanner, the once every two or three months and exhaust of the ehole vehicle. If there
screw down moment is 2.5-30N.m. the time should be 2-3 minutes so as are some troubles, please pay a visit to
to avoid knot glue of the petrol stop up Dongfeng Mini Auto Maintainance
the oil gushing out device. Station.
13. Throttle Valve Block 14. Three -way convertor
12. Oil Sprayer
The exhaust system of the electricity
jet is equipped with three-way
convertor to deal with aftertreatment
46
of exhaust from engine; three-way which should be adjusted.
convertor can reduce the harmful gas
18.ABS
ABS (Antilock Braking System, ABS
effectively. for short) can prevent wheel from
braking completely suddenly by
It is quite easy for three-way convertor automatically and repeatedly adjusting
to be overheated while the gasolines the braking pressure and fully utilize
engine working, and which may cause peak value of the adhesion coefficient
the damage of the three-way convertor. among the tire and ground and high
Turn the steering wheel slowly from lateral force coefficient while applying
In order to protect three-way convertor, left to right to check its idle stroke.
while the driver is in the course of the brake promptly to gain the
The idle stroke of steering wheel manipulation of the automobile while
operating, please refer to instruction & along the circumference is 0-30mm.
maintainance manual of gasoline applying the brake and the direction
The turning of the steering wheel stability, and there is integrated
engine of DELPHI system or unite should be light and smooth and
electricity systematic electricjet serial control system of electromechanics
without noise. combined by shortest braking distance
petrol machine use and maintain the
manual.
17. Clutch Pedal advanced electronic technology and
mechanical technology.
15. Electric Fuel Pump
The work of ABS systemis automatic,
The fuel-pump is in the fuel tank.
Note: whenever, as long as the apperceive
Do not drive while the oil mass is wheel is locked up, it begin to work
insufficiency, otherwise the fuel pump
automatically. Step on the brake pedal
will be burnt for the fuel has been run
out. directly while applying the brake; do
not step on the brake pedal repeatedly.
The free way of the clutch is 15-25mm,
16. Steering Operation and it is improper for longer or shorter,
47
Note: On decorating road, the braking stepping on the brake pedal by 294N
When ABS loses its function, the distance of vehicle with ordinary (30kg)
performance of brake system is same braking system will be shorter than
with that of the common brak system. that of vehicle with ABS.
. Note:
Please use the tire regulated by the Measure the space between the
instruction manual. Brake Oil Can brake pedals, the stool plate of the
The brake oil can lies in the left upper wainscot and the rubber washer on
19. Brake System part of the outside of the fron the pedal are not included.
storehouse clapboard. Check the brake
oil can, if the oil level lies below the ① The braking force is insufficient.
line’MIN’, please supplement the ② The braking is not stable.
brake oil, the trademark for it is JG3.
③ The stroke for the pedals is too
Brake System
big..
④ .Brake blocked
⑤ Brake with noise
Note: ⑥ The pedal bounced while stepping
To the same vehicle, when applying on.
the brake on some soft road
surface(such as the broken stone road Hand Brake：
surface, snow road), the braking Hold the handle brake rod upwards to
distance of vehicle with ABS is longer When stepping the brake pedal down
Note: check if the rear wheel stopped , and
than that of vehicle without ABS but completely,
Do the different
not mix the distance kinds
‘A’ between
of and check when draw the hand brake rod
with common braking system. If the the pedal and
different typesthe front wall shall
of brake not
liquid upwards by strength of 20kg, if the
vehicles with ABS system please less than 95mm. And it should
together, otherwise which may cause be pole stops in (3-8) ratches.And it shall
reserve longer brake distances. checked
the seriousand
damagemaintained if the
of the braking also be checked that when relax hand
following things happan
system. Do not utilize the old, used while
or
48
unsealed brake liquid.
brake totally, there should be no sense worn and torn and lengthen its service ① Check the wearing and tearing of
of being blocked. life, please make the tires
transposition when it is running every the flower stria to make certain that if
20. Tyre
10000km and adjust the air pressure of it should be changed or not.
front and rear tire to the regulated ② Check if there are abnormal
value (please refer to the pressure
scutcheon on the driver’s side door). wearing and tearing, crack and
When the air pressure is too low, it damage for the tire. If yes, please
will cause the tire worn and torn too
much and difficult to drive and heavy change it.
fuel consumption; while the air ③ Check if there are nail. Carpolite
pressure is too high, the vehicle shakes or other articles pierce into the tires or
The tire trakemark of this vehicle is badlly and cause the stability bad and
165/70R14, and the pressure should be the middle of the tire will be badly embed in the flower stria.
as follows: worn and torn. ④Check if the nut looses. While
The air pressure of the tire should be
replacing the tire please use the same
Loading Fr Wheel RR Wheel checked by the pressure gage.
180kpa 220kpa type, same specification and loading
Zero Load 20. Tyre
capacity tire as the original tire. The
250kpa 290kpa
Fully Loaded Note: flower stria for the four changed tires
When pumping the tyre, pls
20. Tyre slowly pump the tyre and at the same should be the same.
Note time check the tyre pressure until it 20.Tyre
The air pressure shall be reach to the regulated pressure.
Note
measured while it is in the cold
The following check should be carried While replacing the tyres, the four
condition.
tyres shall be the same type.
In order to prevent tire from being out in the course of using:
Note: 49
The spare wheel shall be the yellow
steel wheel which can be only used
when emergency.
Taking the spare wheel as the
the connection end and erosion will
cause poor contact. If the the white
power is found at the connection end,
20. it should be clean up and then spread
lubricate grease or waseline.
22. Fuse
The spare tire is put under the floor of
the back of the vehicle, screw the
fixed screw on the rear pumper
counter-clockwise and put down the
spare tire bracket, and remove it. And
Replacement of the Tyre the fixing and discharging should be
① Take off the jack, tool and spare carried out counter-clockwise to make
There are two kinds of fuses, one is
sure its fastness.
tire from the vehicle. the major fuse and the other kind is
21. Battery the fuse in every part of circuit.
② Loosen the tire, but do not remove
the nut. ①Major Fuse: Bear the
③ Put the jack in a proper position electric current in the battery directly.
and raise it up. When it is burnt, no electric
④Discharge the wheel. component can work normally. If so,
④ Fix the wheel and change the nut. please check the circuit of the
The battery electrolyte level should charging system.
⑥Lower the jack, fix the nut by always be between lines of ‘upper’
spanner. and ‘lower’, if the electrolyte is lower
20. Tyre than ‘lower’, add the electrolyte to the
marking line of ‘upper’. The loose of
50
Note
If the major fuse is burnt, 22. Fuse Note
the users should replace it In order to guarantee that
Note there are spare fuse for
instead of using the wire etc as If the electric machine works
substitute which may cause the replacement, three 10amp and
without cleaning liquid, it will 15amp fuses will be prepared in
damage of the electric system, cause damage. Do not use he
even the fire. the fuse box.
ngine ntifreeze instead of
① Fuse of Branch Circuit cleaning liquid, or else, it will
The fuse box lies in the left of the damage the oil paint. 24. Replacement of the Bulbs
pedal bracket. When taking down the Different Lamp
fuse, first remove the cover of the fuse 23. Air Window Cleaning Note:
box, and then draw out the fuse. In Please replace the bulb when it cools
Liquid
order to differentiate the capacity down.
(amp) position of the fuse, please refer Halogen lamp is very hot while in the
to the indication diagram on the cover course of lighting or at the moment of
of the fuse box. being closed and will damage the skin
Note and cause fire, please wait till it cools
Users should use the right capacity down and take it off by wrapping it
fuse while changing the burnt fuse, with soft cloth.
using the aluminum foil or aluminum If the bulb is frequently burnt, it shows
wire and other substitutions are not that there are some problems with the
allowed. If the fuse is burnt in a very Check the container for cleaning circuit. Please go the Dongfeng Mini
short time, it shows there are big liquid, if there are not enough cleaning Auto Maintainance Station for help.
problems with the electric, please go liquid, please add it
to Dongfeng Mini Auto Maintainance .
Station for help.
51
be simply pulled out or inserted in.
While removing the round bulb from
the socket, please first press the bulb
in and then contrarotate a little and
then pull out.
24. Replacement of Bulb
Push forward the rear fixing foot
after breaking off relations, take out
box cover backward, you can lift off
24. Replacement of Bulb bulb for change.
① Open the front storehouse cover
② Remove two screws and draw out
the headlight forwad.
③ Pull out the flashboard.
④ Remove the pressurized rubber. See the picture, use an opener and
⑤ Push forward the spring making it wrap it with cloth, then pr down the
release from the hook, then change the glass cover to replace the bulb.
headlight bulb. 24. Replacement of Bulb 24. Replacement of Bulb
⑥Contrarotate the fender light or Turning Lights, Side Turning Lights,
tailstock of the turning lights and then Rear Assembled Lights, Liscence
Lights.
removes the bulbs for replacement. There are two forms of bulbs (ellipse
24. Replacement of Bulb or roundness), and the ellipse bulb can
52
53
tailstock of the turning lights and then Don't electrification is it dial ECU
removes the bulbs for replacement plug to insert, is it is it " blow fire "
25. ECU way carry on circuit is it check to set
up an electric circuit " to adopt to
forbid, is it adopt power of
charger ,etc. carry on starting to
forbid, car body is it should remove
ECU when welding to need
26. Ignition Timing
ECU is the key component of
The integrated electric ignition system
electric control system, inside which
for is a totally electric ignition free of
there are designed process and
adjustment. The system has cancelled such
demarcated data for controlling
parts as bypass and contact point etc., and
running. Do not pull out the cable at
the ignition timing is controlled by the ECU
① Open the front storehouse cover. will at any cases so as to avoid the loss 27. Usage of Jack
⑥ Remove two screws and draw out of the data. If there are any troubles,
the headlight forwad. please go to Dongfeng YUAN Auto
⑦ Pull out the flashboard. Maintainance Station for help
⑧ Remove the pressurized rubber.
Note
⑨ Push forward the spring making it Please prevent the ECU from Jack and rock rod of the jack should
release from the hook, then change the water while in rainy day or while
washing be kept in the cover board of the front
headlight bulb
storehouse. After using, please return
⑥Contrarotate the fender light or 25. ECU
to the storehouse and make sure they
54
have been fixed up firmly And any person shall not be under yellow is pressuer over high, red over
the vehicle while jacking up to low, should be changed.
While using the jack, the vehicle shall
prevent the damage to people
be put in the horizontal and hard
28. Extinguisher 29. Triangle Warning Plate
ground. If you stop the vehicle on the The usal and operation of
road, please turn on the emergency Extinguisher
light Take out the extinguisher and pull
the cover then spurt extinguishing
Lock up the parking brake, and put agent in 1.5M distance of root of fire.
gearshift rod in the reverse gear, and Pressure extinguisher valve until
finishing spurting extinguishing agent.
fix the the tire on the cross of the And inversion use not allowed.
rising angle by chock
Note
Put the jack under the jacking 1. Every 2 years change Please refer to the Instruction
position and upright jack up the extinguisher with 450g, and every 4 Manual for the operation guide of
vehicle steadily and slowly to the years change extinguisher with 500g, Triangle Warning Plate
even not use.
proper position; do not jack up the
2．Extinguisher with 450g should Note：Engine is on working during
vehicle too high
change a new after use in appointed switch is ON. Unless is out of line
fatory, while 500g can be fulled the operation.
Note agent and reuse.
Be careful if the vehicle rises
3．450g exginugisher should be
vertically in the course of jackup.
If the jack begins to incline, please checked in appointed factory per year. 30. Operating controller
correct it to the right position. 4．Check the index during green
Jackup on the slope is not allowed. area or not for 500g extinguisher with
pressure gauge. Green is natural and
55
Press UP botton, and keep the normal

31 .Trurning Over and Side speed. When trun over to some angle,
① Pull switch to ON. tightwire pull the switch to limit the
① Stop the car on flat floor. location, then hydranlic pressure
Note the height of room when turn power off, cargo box stop turn over.
over to behind, and insert the ring of When the lifting stop fails, the
limited location, then put double bolt hydraulic cylinder’s max range is
into double groove hole, with bolt ring going to limite the angle of box
of limited location, and check turn-over.
equipment correct or not.
② Take out the lift controller, press

UP button, the hydraulic pressure
motor and buzzer beging working, ① Open lift switch to ON
people apart from cargo box. ① Take out the controller from cabin.
When trun over to some angle,
tightwire pull the switch to limit
the location, then hydranlic
pressure power off, cargo box stop
turn over. Left turn
①Put single bolt into left single
56
groove when turn the cargo box to regarding connecting rod as axle ①Side plate opened by manual.
left,with ring of loctation limited, then rotation that makes latch hook rotate There are lock on the side plate, and
put the double groove bolt into left at the same time, and makes latch lock with cargo box. When close side
rear groove round hole, equip limited hook get rid of box rear plate hinge, plate, the lock clip is in lock station.
ring bolt, and check the equipment then realizes box rear plate open Need open outer handle bar on the
correct or not. automatically. side plate to open the side plate. Outer
② Then operate as above ②③ in handle bar drives the lock interior
trun over operation. construction move to make side plate
Right turn shaft pin downward so that to separate
① Put single bolt into right single from the side plate lock, then open the
groove when turn the cargo box to box side plate.
right,with ring of loctation limited,
then put the double groove bolt
into right rear groove round hole,
equipe limited ring bolt, and check
the equipment correct or not.
②Then operate as above ②③ in When cargo box in normal location,
turn over operation. rear plate can not be closed
operation of rear plate of cargo box automatically, should with manual.
Rear plate of cargo box be open Press the hand shank of rear plate
automatically when the cargo box turn starting connecting rod, make the box ②Then operate as above ②③ in
to some angle. Mainly because the rear plate back to the hinge match turn over operation.
movement relationship between position, then loosen the hand shank, operationg of equip stay bar.
system of rear plate starting make the latch hook and hinge shaft Use the stay bar when turning to some
connecting rod and the starting of box pin fit then the box rear plate will be angle without loading, adjust the flip
rear side-plate back plate. Rear plate closed. angle, to ensure the top of stay bar in
starting connecting rod system is operation of side plate of cargo box its safety area, achieve the purpose of
57
safety. under the vehicle. explosive or sticky material are
Notice: when the dumper is at allowed to be transported by
work, the surrounded dumper truck；
environment should be noticed , Notice： If the cargo box can
if there are flammable things not be lowered due to the battery
around the dump are forbidden. failure or low battery, during
Note： It may lead to accidents Notice: while dumping, nobody operation, the user need to
use the stay bar when goods have not is allowed to stand on the cargo
been full discharge, only use for replace or charge the battery, or
box. inform the repair plant
checking and maintaining cargo box.
nominated by the factory. And a
Note for operation of lift
triangle plate should be placed
around the box to warn the
Note： nitial use, the vehicle should be
loaded in accordance with the initial passers-by. No manual operation
requirements in order to avoid mechanical are allowed to perform to lower
damage. the cargo box。
Note：If need full loading please put
the goods into cargo box in low place
to avoid parts damage.
Note： Lift the cargo box the car
should be in horizontal position to
Notice： the vehicle could not
avoid the accident of over flip. exceed 10km/h when the cargo Notice： When performing
Notice: while the cargo box is box is fully lowered to the dumping operation, personnel
lifting and descending , no original position； should stay away from the
people are allowed to stand Notice： No flammable, dumper when hearing the buzzer
58
alarming； operations are allowed to the
cargo box。
External lubricating spot：1）
ball joint of the hydraulic
cylinder；2）joint of frame ball
joint and the stand ball joint；3）
latching mechanism of the cargo
Rated wattage of the hydraulic box；
Notice： Unauthorized type of lubricant and the
motor：800W; Rated rpm：
personnel must not use and interval between two refills：
operate the power switch of the 4000r； Rated voltage：12V；
The lubricant should be made
dumper truck； Rated current：67A。 from lithium, and should be
Notice： the applicable Pump ： Rated pressure ： refilled and replaced based on
temperature of the hydraulic 8MPa;Rations to the motor： the use of the vehicle.
system of the dumper truck is 0.625； Dump systems hydraulic oil: model
-10˚C-40˚C。 HM 46: HM hydraulic oil developed
Notice ： if the power fails from the antirust and antioxidation
Hydraulic motor： when the cargo box is lifting, hydraulic oil, it has high alkaline zinc,
the manufacturer should be low alkaline zinc, zinc and ash-free
high-neutral-type and other products,
informed to appoint service which according to 40 ˚ C
center or technician to conduct Sports viscosity is divided into four
repair, non-professional must grades 22,32,46,68.
not operate. No forcible Hydraulic oil introduction and note:
59
l）To maintain the cleanliness of hydraulic （3）Storage and use, fuel containers and recommended by the manufacturer or
systems, shou be the timely removal the tools must be clean to prevent oil the product supply applies to the pump
sludge and metal shavings of the fuel tank. contamination load limits.
（2）Reference indicators to change oil, Note: After 5000Km drived, filter
（4）The oil is mainly used in steel - should be changed.
all the equipment parts should be cleaned to
prevent impurities mixing into oil and
steel pairs of hydraulic
pumps. Friction material for other
affected
hydraulic pump, the pump must be
Ⅵ . Check & Maintenance Service
60
Period Km×1000 10 20 30 40 50 60 70 80
Items
1. Daliy inspection Failure moon count as standard confirm
maintain time form. Every inspection ,
Daliy inspection is a necessary 1○3Fuel Level adjust , lubricate should stipulated
work for driver. The conditions of the 1○4Door Lock time go on according to form strictly
vehicle changes every day, so please 1○5Rear Mirror with other maintenance work.
check it before driving, which can Note
1○6Licence Plate
help find the problems and solve them The maintence items with mark
2 、 Regular Check and ‘*’ should be carried out by the
before driving to enable to be safe. special maintainer. While regarding
Maintainance
○ 1 Fan belt
3、Regular Maintainance Perid to items without ‘*’ can be do
○ 2 Engine oil
and Items
maintenance according to the
instructions, and if you think you
○3 Cleaner The following form will introduce cannot do that, please go to the
○ 4 Battery Electrolyte Level some checking items; we can find special maintainer’s of Dongfeng
○5 Engine Coolant problems while checking and take
measures accordingly. The running
Yuan.
○6 Stroke of Brake Pedal kilometers and months will be the
○7 Tire standard maintenance time. The check ,
4 、 Signs for Regular
○8 Free way of Clutch Pedal adjustment, lubricant and other
maintenance service should be strictly Maintenance
○9 Turning Operation subject to the stipulated time in the ‘G’ means change
1○0 Indicator Light & Indicator form.Make form recommend several ‘R’ means needing to be lubriacant.
Meter project of checking emphatically, ‘X’ means screw to the regulated
torque.
○
11Lighting System through is it pinpoint the problems to
check , take the pertinence measure in ‘J’ means checking.
○
12 Instruction of Electric Jet time. With go kilometer count or ‘T’ means adjustment.
61
Months 6 12 18 24 30 36 42 48
Engine
1.Fan（Water Pump、 Compressor）
Drive Branch Belt （ Strain 、 — G — G — G — G
Abrasion ）
*2. Camshfte Synchronization
— J.T.G — J.T.G — J.T.G — J.T.G
Tooth Belt(Strain, abrasion, damage)
*3. Valve Gap — J.T. — J.T. — J.T. — J.T.
*4. Engine Bolt(cylinder cover,
— X — X — X — X
manifold toggle)
5. Oil fillter G G G G G G G G
6. egine oil Replace for every 5000km
7. Engine coolant Infuse at any time
*8. Soft Tube and Tie-in of Colling
System( Soft Tube and Tie-in of
— J.T.G — J.T.G — J.T.G — J.T.G
Colling System(leaking ,damaging
etc.)
*9. exhaust system — J.T.G — J.T.G — J.T.G — J.T.G
5、Maintenance
Periods Km×100
10 20 30 40 50 60 70 80
Items 0
month 6 12 18 24 30 36 42 48
Ignition
*10.
— J.T.G — J.T.G — J.T.G — J.T.G
Ignition Coil(damamged, deformed)
*11. Spark Plug G G G G G G G G
*12.Ignition Timing J.T. J.T. J.T. J.T. J.T. J.T. J.T. J.T.
62
Fuel System
13. Air Cement or asphaltum
Clean while driving for every10000km, replace for every 40000km
Cleaner road
Gravel Road Clean while driving 25000km, replace for every 40000km
*14. Fuel Box, fuel pipe and tie-in J.T.G — — J.T.G — — — J.T.G
*15 Fuel Cleaner G G G G G G G G
Exhaust Control of Crankcase
*16. Exhaust Soft Pipe & Tie-in
J.T.G — J.T.G — J.T.G — J.T.G —
*17.
J.T.G — J.T.G — J.T.G — J.T.G
Fuel Steam Storing Device
*18. PCV Valve — J.T.G — J.T.G — J.T.G — J.T.G
Periods Km×100
10 20 30 40 50 60 70 80
Items 0
monthes 6 12 18 24 30 36 42 48
Electric Equipment
*19. Electric Wiring, Connect & Lamps

— J.T.G — J.T.G — J.T.G — J.T.G
Chassis & Body

*20Clutch J.T. J.T. J.T. J.T. J.T. J.T. J.T. J.T.
*21. Brake Fluid(Liquid
J.T.G J.T.G J.T.G G J.T.G J.T.G J.T.G G
Mass,Leaking)
*22.Brake Pedal(Stroke) J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
*23. Manual Brake Rod & J.T. J.T. J.T. J.T. J.T. J.T. J.T. J.T.
63
Cable
*24. front: Brake disk & cliper J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
*25. Rear: Brake Drum &
J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
Brake Shoes
*26. Brake Soft Pipe &
Pipeline(Leakage, damage)
27. Tire(Abnormal Abrasion,
Abnormal Air Pressure)
28. Wheel & Boss Nut J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
64
Periods Km×1000 10 20 30 40 50 60 70 80
Items monthes 6 12 18 24 30 36 42 48
*29.Bolt & Nut(Elasiticity) — X — X — X — X
*30. Steering Wheel(Gap,
Elasiticity)
Cooling System
*31. Refrigerant
*32.Brake System J.T. J.T. J.T.G J.T. J.T. J.T. J.T. J.T.G
J.T.G J.T.G
*33.Compressor — — — — — —
R R
*34Condensor Check at any time
*35.Evaporator — — — J.T. — — — J.T.
*36. Desiccator — — — G — — — G
*37. Refrigerate Pipeline — X — X — X — X
65
Emergency Measurement
Ⅶ、Analyzing & Eliminating the Malfunction
1、Malfunction of Engine System

Problems Reasons Solutions
Starting Problems 1、Failure of Ignition System Replace
1.1 Damage of the Protecting Device Repair or Replace
1.2 Failure of the Spark Plug Repair or Replace
1.3 Joint of High Voltage Damping Wire Loose or Replace
being Damaged
1.4 Damage of Ignition Coil
2、Failure of Fuel System

2.1 Lack of Gasoline Infuse Gasoline
2.2 Gasoline Cleaner Blocked Clean or Replace
2.3 Fuel Pipeline Defiled or Blocked Clean
2.4 Electric gasoline pump doesn’t work Repair or Replace
66
2.5Impurity Fuel (eg. Including water) Rectify
3. Lack of Crock Pressure Screw Down or Replace

3.1 Spark Plug not Screw Down or Damage of Adjustment
Gasket Repair or Replace
3.2 Incorrect Valve Gap Repair or Replace
3.3 Leakage of Cylinder Cover Gasket
3.4 Piston, piston ring or abrasion of Cylinder
4.Others
4.1 Rupture of Timing Belt Replace
4.2 Vacuum Soft Pipe inconnect Reliable Connect
Decrease/ lack of the 1. Malfunction of Ignition System
Engine Power 1.1 Inprope Spark Plug Gap or Burnt Adjust or Replace
1.2 Poor Connect/ Damage of High Voltage Repair or Replace
Damping Wire
2. Malfunction of Fuel System Clean
2.1 Block of Fuel Soft Pipe or Oil Pipe Clean or Replace
2.2 Block of Gasoline Cleaner or Air Cleaner Repair or Replace
2.3 Oil Supply of Gasoline not enough Clean or Huff
2.5 Trouble with Piston Valve Replace
2.6 Broken gasket of intake branch pipe Replace
2.7 Incorrect fuel trademark
3. Insufficient Crock Pressure As Above Mentioned
67
4. Others
4.1 Brake Problems Repair or Replace
4.2 Clutch Skidding Adjust or Replace
4.3 Connect Flex or Vacuum Soft Pipe Break Off Reliable Connect
Unstable Idle Speed of 1. Trouble with Fuel System

Engine 1.1 Block of the Air Cleaner Clean or Replace
1.2 Leakage of Intake Branch Pipe Replace
2. Mafunction of Ignition System

2.1 Inproper or Burnt Spark Plug Gap Adjust or Replace
2.2 breakoff or creepage of High Voltage Damping Replace or Connect
Wire
3. Lack of Crock Pressure As mentioned above
4. Others
4.1 Connect Flex or Breakoff of Vacuum Soft Pipe Reliable Connect
4.2 Failure of PCV of Crankcase Replace
Abnormal Noise in the 1. Valve Noise
inner side of the Engine 1.1 Inproper Valve Gap Adjust
1.2 Abrasion of Valve Rod & Valve Guide Pipe Replace
1.3 Failure or Damage of Valve Spring Replace
1.4 Distort or Curve of Valve Replace
2. Abrasion of Piston, piston ring and Valve Repair or Replace
68
3. Rod Noise
3.1 Rod Bearing Abrasion Replace
3.2 Winch Pin Abrasion Repair or Replace
4.Crank Shaft Noise
4.1 Bearing Abrasion Replace
4.2 Crank Shaft Neck Abrasion Repair or Replace
4.3 Bearing cover bolt flex Screw Down
4.4 Gas of crank shaft thrust-piece too big Replace the thrust-piece
Engine Superheating 1. Insufficiency of Coolant Complement Coolant

2. Air Resistance in Cooling Sytem gas freeing & adding coolant
3. Loose of Water Pump Belt Adjust
4. Malfuction of Thermostat Replace
5. Poor Performance of Water Pump Replace
6. Too Much Begrime in Cylinder Body AND Repair or Replace
Cylinder Cover Clean or Repair
7. Block or Leakage of Radiator Choosing the right kind
8. Incorrect Engine Oil Kind Replace or Clean
9. Block of Engine Oil Cleaner or trap valve Add
10. Insufficient of Engine oil Repair or Replace
11. Poor Performance of Oil Pump Repair or Replace
12. Brake Seizure Repair or Replace
13. Clutch Skidding Replace
14.Damage of Cylinder Cover Gasket
Consumption of Engine 1. Leakage of Engine Oil
Oil 1.1 Flexible Discharging Oil Bolt Screw Down
1.2 Bolt of the Oil Case Flexible Screw Down
69
1.3 Replace the Sealling Glue

Seal Glue of Oil Case deterporate or Break Replace
1.4 Leaking of Oil Seal Replace
1.5 Damage of the Cylinder Gasket Screw Down
1.6 Engine Oil Filter not being Screwing down Screw Down
1.7 Leaking of the Engine Oil Pressure Annunciator Screw Down or Replace
1.8Oil Leaking of Cylinder Cover Screw Down
1.9 Oil Line of the Cylinder Blocked and leaking
2. Engine Oil Entering the Firebox
2.1 Piston Ring Locked Clean of Sand
2.2 Abrasion of Piton Ring & Groove Repair or Replace
2.3 Abrasion of Piton Ring & Cylinder Repair or Replace
2.4 Piston Ring not Stagger as regulated Adjust
2.5 Abrasion of Valve Oil Seal Replace
2.6 Abrasion of Valve Rod Replace
2.7 Damage of Cylinder Washer Replace
2.8 Breakoff of Rocker arm Screw Screw Down or Replace
High Consumption of 1. Malfunction Of Fuel System
Gasoline 1.1 Fuel Tank, Carburetor or Leakage pipeline Repair or Replace
1.2 Block of Air Cleaner Repair or Replace
2. Malfunction of Ignition System
2.1 High Voltage Damping Wire Flexible or Connect or Replace
Creepage Adjust or Replace
2.3Malfunction of Spark Plug(Inproper Gap, Burnt,
accumulated carbon)
3. Insufficient of Cylinder Pressure As Above Mentioned
4. Others
70
4.1 Poor Valve Seat Repair or Replace

4.2 Brake Seizure Repair or Replace
4.3 Malfunction of Thermostat Replace
4.4 Abnormal Tyre Pressure Adjust
2. Clutch problems
problems reasons solution
Clutch Skid Inproper stroke of Clutch Pedal Adjust the Free Stroke
Clutch Flake Abrased or with Oily Soil Replace Clutch Flake
Deformation of Compressive Plate or Flywheel Replace Clutch Flake, Clutch
Surface Compressive Board or Flywheel
Diaphragm Spring Weak Replace Clutxch Cover
Clutch Cable Rust Replace Cable
Hard Seperation of Inproper Free Stroke of Clutch Adjust Free Stroke
Clutch Diaphragm Spring Weak or Abrasion of Reed Replace Clutch
Input Spline Rust Lubricating
Damage or Abrasion of Transmission Input Shaft Replace Input Oil
Spline Replace Clutch Flake
Serious Sway of Clutch Flake Replace Clutch Flake
Clutch Flake Abrased or with Oily Soil
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Vibration of Clutch Brightening of Clutch Flake (Like Glass) Repair or Replace the Clutch Flake
Clutch Flake with Oily Soil Replace Clutch Flake
Separate Bearing Smoothly Skid on the Guard Ring Lubricate or Replace Input Shaft
of Input Shaft Bearing Bearing Guard Ring
Sway of Clutch Flake or Poor Connection Replace Clutch Flake
Torsional Spring in the Clutch Flake Weaken Replace Clutch Flake
Loose Rivet of Clutch Flake Replace Clutch Flake
Deformation of Compressive Plate or Flywheel Replace Clutch Cover or Flywheel
Surface Screw Down Again or Replace
Fixing Wahser of Engien Becoming Weak, and fixing Washer
Fixinjg Bolt or Nut Becoming Flexible
Clutch Sounding Abrasion or Damage of Separate Bearing Replace Separate Bearing
Abrasion of Front Input Shaft Bearing Replace Input Shaft Bearing
Loose of Clutch Flake Hub Replace Clutch Flake
Crakes in Clutch Flake Replace Clutch Flake
Compressive Plate or the Diaphragm Spring Loose Replace Clutch Cover
Clutch Jammed Clutch Flake Soked with Oil Replace Clutch Flake
Serious Abrasion of Clutch Flake Replace Clutch Flake
Rivet Coming out of Flake Replace Clutch Flake
Torsional Spring Weaken Replace Clutch Flake
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3. Malfunction of Transmission
Off Gear Abrasion of Gearshift Forked Shaft Replace
Abrasion of Gearshift Fork or Synchronizer Gear Replace
Cover Replace
Elasticity of Setting Spring Weakened or damaged Replace
Abrasion of Input shaft or Main Shaft Bearing Replace
Abrasion of Tooth Sleeve etc. Fix
Hatch Spring Ring breaking off
Not Off Gear Elasticity of the Synchronizer Spring Weakened or Replace
the Spring Broken Replace
Deformation of Gearshift Axle or Gearshift Fork
Gearshift Troubled Incorrect Clutch Pedal Stroke Adjust
Deformation or Break of the Cluch Friction Disc Replace
Damage of Clutch Compressive Plate Replace Clutch Cover
Abrasion of Synchronizer Alligatoring Ring Replace
Deformation of Gearshift Axle Replace Gear
Replace
Noise Insufficiency Lubricant or the Inproper Type Complement or Replace
Damage or Abrasion of Bearing Replace

Dmage or Abrasion of Gear Replace
Damage or Abrasion of Synchronizer Alligatoring Replace
Ring Replace
Abrasionor Damage of Gear Sleeve etc.
73
4. Malfunction of Differential Gear

Problems reasons solution
Gear Noise Gear Oil going bad or including water Replace Oil & Re-infuse
Insufficient Gear Oil or Incorrect Kind Replace Oil or Infuse
Incorrect Gap between Taper Driving Gear & its Adjust
Driven Gear Adjust or Replace
Inproper Connect between Taper Driving Gear & its
Driven Gear Replace or Screw Down Again
Loose of Setting Bolt of Taper Driven Gear Replace
Damage of Differential Gear or Driving Gear
Bearing Noise Gear Oil going bad or including water Replace Oil & Re-infuse
Insufficient Gear Oil or Incorrect Kind Replace Oil & Re-infuse
Damage of Taper Driving Gear Bearing(noise Replace
sending off while Gliding)
(Noise while rotating,) Damage of axle bearing of Replace
differential gear or the back axle bearing
Oil Leakage Chock of Vent Blocked Clean

Abrasion or Damage of Oil Seal Replace
Too Much Oil Adjust Oil Level
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5. Malfunction of Steering System, Suspension System, Wheel and Tyre System

Wheel Tyre not matching or Asymmetry Replace
Running(deviating ) Inproper Tyre Pressure Adjust the Tyre Air Pressure
Rupture of Spring Replace the Spring
Belt Tyre Warped by Transverse Force Replace the Tyre
Maladjustment of Front Wheel Alignment Check & Adjust the Front Wheel
One Running Wheel Seizure Alignment
Or Rear Suspension Flexible, Bent or Damaged. Repair Brake
Screw Down or Replace the
Suspension
Abnormal Abrasion or Sagging or Damage of Spring Replace Spring

over-Abrasion of Tire Imbalance of Tire Adjust to make it Balance or
Maladjustment of Front Wheel Alignment Replace Tyre
Trouble with Strut (Shock Absorber) Check & Adjust Front Wheel
Bad Road Condition Alignment
Overloading Replace Strut
Tyre not Transposition Replace Tyre
Abrasion or Sagging of Wheel Bearing Replace Tyre
Sway of Wheel or Tyre Replace or Reposition
Insufficient of Air Pressure of Tyre Replace Wheel Bearing
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Replace Wheel or Tyre

Adjust Air Pressure of Tyre
Wheel Shocked Inproper Strut (Shock Absorber) Replace Tyre
Replace Strut
Front Wheel Shake or Imbalance of Tyre or Wheel Banace the wheel or replace the tire
Jump Abrasion or Damage of Wheel Bearing and/or wheel
Abrasion of Steering Horizontal Coupling Bar Replace the wheel bearing
Abrasion of left/right front Suspension Wall Round Replace the end of turning sidelong
Head coulping bar
Immoderate wheel radial jump Front suspension arm
bulge or damage on the tire Repair or replace wheel and/or tire
Tyre/wheel radial jumping overloadingly Replace the tire
Maladjustment of Front Wheel Alignment Replace tire or wheel
Turning Driving Rodbecoming flexible or being Check & Adjust the front wheel
abrased alinment
Fixing bolt of turning gear box becoming flexible Screw down or replace the driving
rod
Screw down the turning gear bolt
Turning Problems Inproper Charge Pressure of Tyre Charge the Tire to the Proper
Sluggish of Steering Global Scolex or L/R Global Pressure.
Scolex of Suspension Arm Replace the Steering Global Scolex
Maladjustment of Front Wheel Alignment or the front Suspension Arm
Inproper Adjustment of Rack and Pinion Check & Adjust Front Wheel
Sluggish of Steering Wheel Alignment
Check & Adjust the Torque of the
Rack & Pinion
Repair or Change
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Turning Windage too Big Abrasion of Wheel Bearing Replace Wheel Bearing
Bolt of Turning Gear Case Loosened Screw Down

Incorrect Adjustment of Rack & Pinion Check & Adjust Torque of Rack &
Abrasion of Turning Axle Universal Joint Pinion
Abrasion of the turning sidelong coupling bar end Replace Universal Joint
or its inner side global joint. Replace the turning sidelong
Abrasion of Global Joint of Left/Right front coupling bar end or turning sidelong
suspension arm. coupling bar
Replace Front Suspension Arm
(Poor return(Turning) Jamming of turning sidelong coupling bar end. Replace the turning sidelong
Jamming of Global Joint coupling bar end
Jamming of Steering Volume Replace Front Suspension Arm
Poor Lubricant of Rack & Pinion Repair or Replace
Maladjustment of Front Wheel Alignment Check, Repair or Lubricate the Rack
Improper Adjustment of Rack & Pinion & Pinion
Improper Charge Pressure of Tyre Check & Adjust Front Wheel
Alignment
Check & Adjust Torque of Rack &
Pinion
Adjust Air Pressure of Tyre
Noise while Turning Bolt of Turning Gear Case Loosened Screw Down
Wheel Bearing Damaged or with other problems Replace
Abrasion of the turning sidelong coupling bar end Replace
Improper Adjustment of Rack & Pinion Check & Adjust Torque of Rack &
Pinion
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Abnormal Noise with Abrasion of unworkable or loose of the turning Replace the Turning Sidelong Coupling
Front Wheel sidelong coupling bar end, global joint (left/right Bar End, Front Suspension Arm, global
front suspension arm), inner side global joint of the joint and tramsmission shaft joint.
coupling bar or tramsmission shaft joint. Repair or Replace
Damage of Strut or fixing piece Replace
Abrasion of suspension arm bush Screw Down Bolt, Replace Bush
Stabilizer bar becoming flexible Screw Down Wheel Nut
Nut of wheel becoming flexible Screw Down the Bolt or Nut
Bolt or nut of the suspension shelf becoming Replace Wheel Bearing
flexible Replace Spring
Damage of the wheel bearing or other problems Infuse Lubricant or Replace Strut
Damage of the spring of the suspension shelf Bearing
Poor Lubrication or Abrasion of Strut Bearing Replace
Abrasion of the joint of stabilizer bar
Sway while Turning or Tyres not Matching or Air Pressure Odds Replace Tyre or Charge the Tyre to
Turning with Poor Front Suspension Arm Ball Joint and Turning Sidelong Proper Pressure
Stability Coupling Bar End Becaming Flexible Replace suspension arm or the end
Shock Absorber/Stanchion or Fixxing Piece Going Wrong of turning sidelong coupling bar.
Stablization Pole Becoming Flexible Replace Strut or Repair Fixxing
Damage or Sagging os Spring Piece
Inproper Adjustment of Rack & Pinion Screw Down or Repair the Stablization
Inproper Front Wheel Alignment Pole or Cover
Connecting Ball Joint of The Stablization Pole Becoming Replace Spring
Flexible Check & Adjust Torque of Rack &
Pinion
Check & Adjust Front Wheel
Alignment
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Turning Instable while Abrasion of Wheel Bearing Replace Wheel Bearing

Brake Damage or Sagging of Spring Replace Spring
Charge of Tyre Insufficient Charge the Tyre to Proper Pressure
Front Wheel Alignment Inproper Check & Adjust Front Wheel
Alignment
Height of the actural Rupture or Sagging of Spring Replace Spring
vehicle disaccord Overloading Check Carrying Load
Inproper Use of Spring Replace Spring
Feel loose while driving Shock Absorber or Strut with Troubles Replace Shock Absorber or Strut
Suspension suppressed to overload check load
the bottom failure of shock-absorber or support change the shock-absorber or
deflexion or shaking spring shows failure or drooping support
while body truning stabilizer bar loose change spring
failure of shock-absorber, support or installation tighten the stabiliaer bar scew or
parts change bush ot joint
damage of spring or droop change support or installation parts
overload change spring
check load
tyre turns into spill Fr. Support is defect change
wheel bearing abrasion change wheel bearing
tyre and wheel over-run out change tyre and fahuun
abrasion of Fr. Cantilever joint change Fr.cantilever
tyre not balance regulate tyre balance
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6. Warm braw system failure

problems causes resolution
when the warm-braw fan fan fusing change fuse, check short circuit
puts through the power fan resistance doesn’t work check circuit condition
it doesn’t work fan monitor doesn’t work change monitor
circuit or ground connctoion failure repair when necessary
output temperature is control dragline crack or winding check the dragline
wrong air damper damage repair damper
air pipe block repair air pipe
warm braw module leak or block change warm braw module
warm braw pipe leak or block change the pipe
7. AC system failure
problems reasons resolution
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no cooling air output (AC AC doesn’t work Recall, pump-out and fill in cryogen.
doesn’t work) 1) no cryogen check the fuse,heating ventilation
2) fusing change AC fuse and check
3) the switch of AC and fan are wrong short-circuit or not
4) low idling check AC and fan switch
5) AC thermisor is wrong check and regulate AC idling
6) AC water-temperature sensor is wrong check AC thermistor
7) high and low voltage switch is wrong check AC water-temperature sensor
8) top AC relay is wrong check high and low voltage switch
9) accelerate cut switch is wrong check top AC relay
10) circuit or ground connection is wrong check accelerate cut switch
11) AC amplifier is wrong repair as needed
check AC amplifier
compressor is wrong(doesn’t work) check compressor thermol protector
1) compressor thermol protector check electronmagnetism clutch
2) electronmagnetism clutch is wrong tighten or change drive belt
3) drive belt is loosened or damaged check compressor
4) compressor is wrong
freezing fan doesn’t work change fuse and check if
1) fusing short-circuit
2) AC freezing fan relay is wrong check freezing fan relay
3) circuit or ground connection is wrong repair as needed
4) AC freezing fan module is wrong check freezing fan module
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blowing machine module doesn’t work check blowing machine module

1) blowing machine module resistance is wrong resistance
2) ACand fan switch is wrong check AC and fan switch
3) circuit or ground connection is wrong repair as needed
4) blowing machine module is wrong check blowing machine module
No cooling air or not cool cryogen is shortage or overloaded check cryogen condition
enough (AC system is freezing machine block check system leak, check freezing
normal) evaparation block or frozen machine
AC thermostor resistace is wrong check evaparation
AC controller is wrong check AC thermostor resistance
expansion valve is wrong check AC controler
cistern/drier block check expansion valve
drive belt is slipping check cistern/drier machine
electronmagnetism clutch is wrong check or changdrive belt
No cooling air or not compressor is wrong check compressor

enough air (AC system is AC system has air change cistern drier machine,
normal) air leak from top evaporation or air-pipe pump-out and fill cryogen, repair
warm braw and ventilating device system is wrong when necessary
blowing machine module is wrong check evaporation assy
AC system exsists overloaded compressing oil check warm braw assy
check blowing machine fan assy
pump-out AC system compressing
oil and change another compressor
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cooling air output off and Failur of the connection of the circuit Repair when necessary
on Failur of the expansion valve Check the expansion valve
Excessice moisture in the AC system Change the fluid/airer, refill the
Failur of the disconnection switch of high-speed cryogen
Failur of the AC controller Check the failure of the
Failure of the electromagnetic clutch disconnection switch of high-speed
Failur of the compressor overheat protector Check the AC controller
Excessive refill of the cryogen Check the electromagnetic clutch
Check the compressor overheat
protector
Check the capacity of the cryogen
Cool air only during Cool air only during high-speed driving Check the condensor
high-speed driving Inadequate refill of cryogen Checki ts
Air in the AC system Replace the airer, and the evacuate
Slipping of the drive belt and refill the cryogen
Failure of the compressor Check or replace the drive belt
Check the compressor
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No cool air only during Failure of the disconnection switch of high speed Check the disconnection switch of
high-speed driving Excessive refill of the cryogen high speed
Freezing of the evaporator Check the cryogen
Check the evaporator
Check the thermistor of AC
Cool air not strong Jam in the evaporator Check the evaporator
Leak in the cooling device or the pipe Check the thermistor of AC
Failure of the motor of air blower Check the blower motor
Failure of the circuit or ground connection Repair when necessary
Noise in the compressor Rotary valve fails Replace

Bearing valve fails Replace
Cylinder or axel fails Replace
84
Noise in the The bearing fails Replace

electromagnetic clutch Clutch disk damaged Replace
Inadequate cool air The gasket is damaged Replace

The leaf valve fails Replace
No rotation The rotary valve is blocked, causing the jam of the Replace
cylinder and/or the axle Replace
The electromagnetic clutch is stuck Replace
The rotation components get stuck due to
inadequate oil
85
Oil or fluid leak Sealing of the axle is damaged Replace

O ring damaged Replace
8. Brake system failure

Problem Reasons Treatment mothod
Noise when braking Brake pipe leakage Identify and repair leaking parts
Brake disc or brake pad (block) dirted by the oil Clean or replace
Brakes overheating Repair or replacement
Brake drum brake shoe is bad Repairing, so that the correct access
Brake shoe linings are oil or water Replacement
Brake pad (block) linings wear Replacement
Brake Cylinder Damage epair or replacement
Brake caliper assembly failure Repair or replacement
(If fitted) LSPV improper adjustment of sensor Check or adjust
length of the spring Exhaust
The system with air Replacement
Damage to the sensor spring LSPV Replacement
LSPV damage to the rings (if fitted) Refer to ABS System
Anti-lock braking system (ABS) failure (if fitted)
86
Uneven brake (brake work Brake pad (block) friction lining and / or the brake replacement
uncoordinated) shoe linings of water or oil Check the automatic adjustment of
Brake drum brake and brake shoe clearance disorders mechanical
(automatic adjustment of mechanical failure) Replacement
Brake disc brake and / or loss of brake drum circle Uniform inflation
Uneven wheel pressure Repair or replacement
Brake Cylinder Failure Required adjustment
Bad front wheel adjustment Should use the same axis the same tire
Not match the tires on the axle tread Check the hose to soften the tubing
Poor brake lines or hose flow is damaged, with new brake hoses and a
Brake caliper assembly failure new double-decker steel replacement.
Loose suspension components Check the piston is stuck or
Loose caliper slow-moving, should be properly
lubricated bushing sliding calipers,
caliper should slide.
Check all suspension mounting
Inspection, bolt tightening torque in
accordance with regulations
Noise (not brake squeak Friction and wear of front brake linings Replace linings
when issued)
Locking rear brake too LSPV improper adjustment of sensor length of the Check or adjust
early (for a car equipped spring Replace assembly
with LSPV) LSPV assembly failure
Brake locking (for cars ABS system failure (ABS-antilock braking system) Refer to ABS System
equipped with ABS)
87
Too much pedal travel Partial failure of brake system Check the brake system, when necessary,
Inside the brake master cylinder brake fluid reservoir
for repairs.
insufficient Brake fluid with a qualified endorsement.
An air brake system (pedal like riding in the sponge on
Check brake system for leaks, with or
the weak) without air.
Can not adjust the rear brake system (automatically Check the warning lights to the system
adjust mechanical failure) when necessary to exhaust.
Bending brake shoe Exhaust
Rear brake shoe wear Automatic adjustment of mechanical
repair, adjust rear brake
Replacement brake shoe
Replacement brake shoe
Brake Back-bit delay (the Master cylinder piston can not return the correct Master cylinder repair
release of the pedal, the position Check the hose is softening, oil is
brake pedal can not go Brake lines or hose blocked traffic smaller damaged, with new brake hoses and a
back in time in situ) Parking brake on the rear brake adjustment is not new double-pipe replacement.
Brake return spring is not within the return bit or Inspect and adjust the technical
damage requirements
Ying or parking brake pull rod slow response Replacement
Wheel brake caliper piston pump or a stuck Repair or replacement
Caliper piston seal within the severe wear Repair if necessary
ABS (Antilock Braking System) fault Replace piston seal
See ABS System
88
Pedal hopping (when the Damage or loose wheel bearings Replace wheel bearings
brake pedal beat) After steering knuckle or axle deformation After the replacement of steering knuckle
Radial brake disc is too large or does not meet the or axle
technical requirements of parallel Check, if you do not meet the technical
Loss of rear brake drum circle requirements of the brake disc to be
replaced or repaired
Check the runout, where necessary,
repair or replace the brake drum
Brake Noise Brake shoe polish or stick with impurities Repair or replacement
Brake shoe wear or distortion Replacement
Loose front wheel bearings Replacement
Deformation or loose floor mounting bolts Replace or tighten the mounting bolts
After starting the engine Release the parking brake is not Release the parking brake, check and
brake warning light Brake fluid is not enough turn off the brake warning light filling
Implementation of the Brake pipe leakage the brake fluid
brake, the brake warning Brake warning light circuit fault Check for leaks parts, repair, filling the
light ABS (anti-lock braking system out) fault (if fitted) brake fluid
Brake pipe leakage Overhaul brake light circuit
Brake fluid is not enough Refer to ABS System
Check for leaks parts, repair, filling the
brake fluid
Filling the brake fluid
Parking brake, the brake Brake warning light circuit fault Replacing light bulbs or repair circuits
warning light does not
shine
89
After starting the engine ABS (Antilock Braking System) fault Refer to ABS System
ABS warning light (if
fitted)
Implementation of the ABS (Antilock Braking System) fault Refer to ABS System
braking, ABS warning
light (if fitted)
9. ABS system failure (optional)
Check 1
Steps Operation Yes No
1 1) When the ignition switches off, remove the Proceed to step 2 Replace ABS wheel speed sensor
ABS wheel speed sensor. assembly.
2 ） Measure the resistance of ABS sensors
between terminal connectors are in the
1.4-1.8KΩ range (at 20 ° C, 68 ° F
environment)
2 1）Disconnect the ignition switch Proceed to step 3 ABS wheel speed sensor cathode
2) Disconnect the ABS control module circuit with the power supply short
connectors circuit
3）Check first with the sensor and the ABS
control module terminal is properly connected
4）If all goes well, then close the ignition
switch and measure the positive voltage
between the sensor terminal of module plug
connector and ground columns, whether the is
OV.
90
3 1）Disconnect the ignition switch Proceed to step 4 Open-type short circuit grounding
2 ） Connect ABS wheel sensor connectors
connect
3）Measure the resistance between positive
terminal of ABS wheel speed sensors and plug
connector module negative, between positive
terminal and ground.
Check the measured resistance value is reached
the scope of above step 1.
1）Remove ABS wheel speed sensor Proceed to step 5 Cleaning, repair or replace
4 2）Check sensor damage or whether there exists
a foreign body, to see if it is in good working
condition.
5 Visual ABS wheel speed sensor mounting holes Proceed to step 6 Cleaning, repair or replace
(front wheel) or remove rear drum (rear wheel)
and check the following points
If rotor teeth miss or damaged teeth
If no foreign body attached
Whether the eccentric rotor
If the gap of wheel bearings is too huge
Good condition?
6 1）Install the ABS wheel speed sensor to the Proceed to step 7 Replace ABS wheel speed sensor
steering knuckle at .
2）As per required torque, tight sensor bolt and
check the gap between sensor and steering gear
ring, everything is okay?
91
7 See chapter "front wheel speed sensor With a well-known Replace the sensor and re-check.
information" content, check that the output ABS control
voltage or waveform. module replaced
and re-check
Check 2
Steps Operation Yes No
1 1）Turn the ignition switch off, remove the Proceed to step 2 Exclude or replace the ABS hydraulic
device from the ABS hydraulic connectors. unit
2）Check the ABS hydraulic unit solenoid
valve terminal if it is connected correctly.
3 ） If correct, then under this section,
"hydraulic device, the solenoid valve check"
to check the contents of the resistor and the
solenoid valve if it is shorted to ground.
If it is condition?
2 1）Disconnect the ignition switch Proceed to step 3 "W / G" circuit open
2 ） Measuring solenoid valve connectors,
wiring harness side of the terminal "W / G"
and the resistance between the Ground, to see
if it’s connected?
92
3 1 ） Remove the ABS control module Proceed to step 4 "R", "R / W", "B1", "B1 / W", "Y", or "Y
connector / W" short circuits and power supply
2）Check the ABS control module terminal
"A1",
"A2", "A7", "A8", "B12", "B13", whether the
current valve circuit connected correctly.
2 ） If the connection is good, measure
to-ground voltage of module terminal A1,
A2, A7, A8, B12 or B13- (ignition switch is
closed), to see if it’s OV.
4 1）Disconnect the ignition switch With a "R", "R / W", "B1", "B1 / W", "Y", or "Y
2 ） Connect the connectors to the ABS well-known ABS / W" circuit is open, poor contact or
hydraulic unit. control module short-circuited.
3）Measure the ground resistance of module replaced and
terminal A1, A2, A7, A8, B12 or B13, to see re-check
if it’s connected.
10、Power system failure

Problem Reason Treatment
Turn on the ignition switch, the Fuse blown Check the fuse
engine is not running, the charging Lights burned out Replace Lamp
light does not shine Loose wire connections Tighten fittings
IC regulator or field coil failure Check the generator
Bad brush and slip ring Repair or replacement
93
When the engine is running, charging Loose or worn drive belt Adjust or replace drive belt
light does not go out (batteries need IC regulator or alternator failure Check charging system
frequent recharging) Line fault Repair line
11、Variety of lamps, light system failure

Headlight failure
Headlights are not bright Bulb damage Check that the lamp
Faulty headlight switch Check the headlight switch
Headlights (left and right) are blown fuse Check the fuses left and right, if
Faulty wire or ground necessary, to be replaced. (If
replacement, check whether the
short-circuit)
Repair line
Only a headlight is not lit Bulb damage Check that the lamp
Headlight (left or right) fuse blown Check the fuse, if necessary, should
Faulty headlight switch Check the light switch front
Faulty wire or ground Repair line
Front anti-fog lamp failure
94
Front anti-fog lamp doesn’t work

Bulb damage Check the lamp
Fog light fuse blown Check the fuse, if necessary, should be
Front anti-fog lamp switch doesn’t replaced. (If replacement, check if it’s
work short-circuit)
Front anti-fog lamp relay doesn’t work Check front anti-fog lamp switch
Front headlamp switch doesn’t work Check relay
Wire or ground connection doesn’t Check switch
work Repair line
One of anti-fog lamp doesn’t Bulb damage Check lamp
work. Wire or ground connection doesn’t Repair line
work
The failure of turn signal and emergency warning light

Flash frequency is too high, or Damage to the side of the bulb Check lamp
only one side Flash Lamp is not configured correctly Check lamp
Turn signal / emergency alarm relay Check relay
failure Repair line
The open or resistance between turn Repair line
signal / emergency alarm switch and the Check the fuse and replace
Doesn’t flash light is too large If replacement, check if it’s short-circuit
Wire or ground connection doesn’t Check the bulb and check the line
work Check relay
Backup horn or reversing lights blown Check at the beginning
95
fuse
On or resistance between battery and
switch is too large
Turn signal / alarm relay faulty
Combination switch or alarm switch
doesn’t work
Flash frequency is too low Supply voltage is too low Check recharging system
Turn signal / urgency alarm relay faulty Check relay
Problems Reasons Solution

Braking warning light is Stop brake is not released Release the stop brake, check and turn
on when starting the Short of brake liquid off the braking warning light and infuse
engine brake pipe leaking brake fluid.
Braking warning light is Circuit problems with the brake warning light Check the leaking position, repair and
on when braking Trouble with ABS(if there is) infuse brake fluid.
brake pipe leaking check the circuit of breaking light
Short of brake liquid Please see ABS
Check the leaking position, repair and
infuse brake fluid.
Infuse brake fluid
Braking warning light is Trouble with the circuit of braking warning light Replace the bulb or repair the line
not on while stop braking
96
ABS warning light will be Trouble with ABS Please see ABS
on while starting the
engine (if it has)
ABS warning light will be Trouble with ABS Please see ABS
on while braking(if it has)
97
Ⅷ 、Disposition of Emergency
1. Starting System Not Work headlight is opened, try to turn thee state. If headlight becomes too dark or
①In a situation that the ignition switch to " START " position goes out totally, it generally shows the
in order to confirm the storage battery storage battery electricity exhaust or
98
poor connecting of wiring end. After not bend over the battery. respectively. Pay attention that the
Confirmation, charge the storage ②Do not expose the battery to direct cable shall not be near to the belt
battery or repair the connect point. fire or make it under the spark. pulley, belt or fan.
③Keep your eyes & skin away from ③Start the engine of the vehicle with
②If the headlight keeps being on, battery first, then start the engine of
the storage battery acid. If any part of
please check the fuse. If there are still the skin touches and holds the acid the vehicle without electricity.
liquid of storage battery, wash the ④Do counterclockwise according to
problems, there may be big electrical injured area completely with water the above orders to backout the
immediately, and ask doctors and connected cables.
problems; you should go to Dongfeng nurses for help.
Note
YUAN Auto for repair. Please follow the following If battery is installed again
after being removed, the original
2. Instruction of Storage Battery instruction while parallelizing the designed condition will lose in
Connect Start battery to start: ECUand you may find the idle
If the engine can not start because of speed is too high or too low
the storage battery, you can connect ①Put one good 12V storage battery when re-starting this is not a
Note
one kind storage battery in parallel or close to vehicle, and make the link trouble and it is unnecessary to
storageStorage
battery battery can for
to change produce
starting cable reach to the storage battery. adjust, the ecu will adjust the idle
explosive gas, and the causticity
in order to help to supply enough Make the two vehicles close to each speed to the regulated value after
acid inenergy.
electric which and the big output other but not touch each other while running 15 seconds at idle speed.
electric current may cause to be using the storage battery on the other
burnt. In order to reduce vehicle.
personnel's injury, you should ②Connect the two ends of the first
follow following information cable with the anode of the 3. Overheating of Engine
when work near storage battery. corresponding battery, and two ends of Under the abominable condition
the cable shall be connected to the of driving a vehicle, the tempreture of
①Make you eyes protected, and do cathode of the corresponding battery engine will temporarilygoo beyond. If
99
the temperature form of the engine is

letting out is found, it is forbidden to
pointedkout beyond the regulated
value, so: use the engine before getting rid of the
①Turn off the A/C. trouble.
③ Parking the vehicle in a safe place,
and make the engine running for c. If no leaking is found, you can
several minutes at idle speed till
the value of the water thermometer infuse coolant to store liquid barrel
go down to the safe range. Traction of the Vehicle
and then to the radiator carefully if If need traction, please send for
③If the tempreture of the water still
necessary. professionalist or special maintainer of
does not go down, please check the
Dongfeng YUAN Auto.
following items:
a.Check and verify whether the water Note: 80km The traction distance
pump belt and belt pulley damage and If the deflation is to be seen or shall not exceed 80km/h.
skid, and the working condition of the heard; you should stop the The traction speed shall not
fan when the engine operates. If there vehicle and turn off the engine exceed 50km/h.
are othe thing abnormal, please adjust to make it cool. If not, you
it or fix a breakdown. should open the engine cover, Note
check if the collant boiling, if In order to avoid damaging
b. Check the coolant level in the your vehicle in the vehicle
yes, wait till it stops.
water tank, if its location is lower than traction, please adopt the
correct equipment and steps
" LOW " line, please look for the leak 4. Traction of the Vehicle while traction.
Don't adopt the way in which
point in water pump , radiator and
the rear wheel land while
water pipe junction, if position of drawing otherwise may cause
the damage of the gear box.
100
firmly by special lock framework.

Note If you use the front traction euippment
Unless
While theemergency,
vehicle is do not towaway,
dragged the the to tow from the front part, the rear
vehicle by transporting pothook wheel shall be fixed to a moveable
front wheels land and the rear
generally.
platform. There are transporting
wheel.lifted. Put the ignition switch on pothook at front and rear end, which
‘ACC’ position to unlock the steering is only use for transportation.
wheel, the front wheel faces just in the
front. The steering wheel is locked up
101
Vehicle Protection
Ⅸ、Maintenance of the Vehicle
102
Vehicle Protection
1. Cleanness of the Vehicle Inside
Vinyl Plastics
water & neutral soap from ethylene ③The scratch of the body
plastic. Make the dirt soft with brush, caused by dirt or other things may
Make the spare liquor by mixing and then, washes the floor cushion result in rust.
the soap or neutral detergent and warm completely by water, and dry by airing
water. Spread the liquor to the vinyl ④The dirt will corrode the car
in the shady and cool place. body. So the more important thing is
plastics; make the dirt soften by
soaking several minutes. Polish the Note that your car should be kept clean,
internal and external surface of car Do not use varnish thinner, without dirt always, and keeps the
thus to remove the dirt and soap with petrol such volatility solvent or cover paint in good condition to
the clean warm cloth. If there is dirt such materials as bleaching agent, protect the body from being corroded.
that still stays on the surface, repeat house using strong syringe while Cleaning:
above-mentioned procedures. scrubing inside and outside of the
The following should be
car. The above-mentioned material
Cleanness of Fiber Material followed while washing the vehicle:
may be toxicant or flammable; it
Use the dust catcher to clean dust, will cause the bodily injury or the ①Wash the bottom of car body
wipe the dirty place with the clean vehicle to damage by improperly in order to remove the mud and grit
cloth soaked with the gentle soap use. with the high-pressure water. Make
liquid, and then wash with the branch dirt with a little bigger water soft so as
water. to clean up completely.
2. Cleanup & Wax of the ②Remove the outside mud and
Cleaness of Safety Belt
Vehicle’s Outer Part dirt of car body with the running water.
Wash the safety belt by water and You can use the sponge stained with
The dirt or any other things on
soap. Don't use bleaching agent or the the paint will cause the following water, the brush or the similar tool
dyestuffs to the safety belt; they will make
the intensity of the safety belt decrease. problems as time goes on. don't be used or it may scratched and
①Cover paint Fades replied the hard material which covers
Cleaning of the Floor ②The degradate lacquer film the paint.
Usually the filth can be cleaned up by causes the car body to get rusty. ③Wash the outer part of the vehicle
103
Vehicle Protection
with sponge or soft cloth which some goods like corrosivity material
dipped into neutral detergent or wash Waxing articles, such as chemical article,
soap for petrol gently. You are advised to make the fertilizer, cleaning the article , alkali ,
④Once after the dirt is removed vehicle waxed & polished after sour , salt ,etc., which should be
completely, wash the detergent with washing to make its cover paint packed in the special container to
the running water. protected and brighter. transport , if there are leaking or
⑤After washing, clean the car ①Only wax and polishing overflowing, please clean up
body gently with the wet cloth, and compound with high quality can be immediately.
dry it in the shady and cool place by used. d. Don't park your automobile in
air. ②While using wax and polishing the car moistly, poor ventilation place,
⑥Check the spray paint surface compound, please pay attention to and don't wash the automobile in the
following proceedings that the manufacturer garage.
to see if there are damages needing to stipulates.
be repaired. e. Don’t spread the primer and
③The chromed parts shall be preventive oil paint layer on or around
2. Cleanup & Wax of the waxed too. the exhaust system so as not to cause
Vehicle’s Outer Part 2. Cleanup & Wax of the the fire.
a. Clear up all damaged part and Vehicle’s Outer Part
Please do not wash the
a. The damage of the auto’s surface plastic parts by steam and
dry. and the comeoff of the paint layer water whose temperature is
b. Mix the paint round, and should be repaired immediately, do
above 82℃.
repaired the damaged place gently not make metal exposed to the air for
with the small brush. a long time.
b. The moisture content, dust,
c. Dry it up after painting. silt under the mat of the auto room can
Copywright Reserved
While using the cleaning agent, the
After washing, please check accelerate the corrosion of the vehicle.
following precautions of manufacturer's
whether there are water entering So, please keep the vehicle clean.
regulation should be paid attention to.
the brake or not. If yes, please Don'tc.useWhen
strongloading and detergent
house using unload
stepped on the brake repeatedly or soap. 104
and slowly to dehumidify it
during driving a vehicle at a
low speed.

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2019 DFSK Extended Cab Truck

3. Serial Number of the Engine

Ⅱ. Main Technical Parameter

2. General Function Index

5. Main weight Parameters

6. Wheel Alignment Parameters

7. Tyre Air Pressure

9. A/C System Parameters

B. Parameter of Mini Truck

2. General Function Index

5. Main weight Parameters

6. Wheel Alignment Parameters

7. Tyre Air Pressure

Ⅲ.Vehicle Devices & Mechanics Operation

10. Lighting, turning and high/low beam control pole

22. Tool box

19. Brake system

31. Turning over and side

5. Malfunction of steering system, wheel and tyre system

Ⅸ. Maintenance of the Vehicle

I.Identification of the Vehicle

1. Identification of Number 2. VIN 3. Serial Number of the Engine

C： Main Parameter Code

D： Serial Number of the Product

2) The VIN should be marked on the side

Ⅱ. Main Technical Parameter

A. Parameter of Mini Bus

5. Main Weight Parameters

6. Wheel Alignment Parameters

7. Tyre Air Pressure

9.A/C System Parameters

Note：1. EQ636×××series include：EQ6360LF；

B. Parameter of Mini Truck

Fuel Consumption L/100

7. Tire air pressure

Note: 1. EQ1020TF truck series includes: EQ1020TF 2.3M,2.5M,2.7M；

Ⅲ、Vehicle Devices & Mechanics Operation

1. Door While locking the front and back door

Press down the button 4, then button 3

8. Dashboard 1○4 Emergency Switch 9、Side Intake

the wiring can be put through and the

control pole be loosen, when there is no

There are four gears Note:

No cleaner and single-arm

Press down the button, all the four

16. Heating System:

①Defrost Exhaust Valve of Windshield

①Windshield defrosting air door

The odometer has six -figure number

While driving, the water

While the pointer at the ‘F’position, it

When the ignition switch is on the

When every headlight adopts high

Adjust the outer rear-view mirror

Ⅳ、Operation of the Vehicle

1.Running-in The first

Ⅴ. Guide for Vehicle Operation

There is 0.3MPa in the oil supply

Press UP botton, and keep the normal