2019 DFSK Extended Cab Truck. Service Manual

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.

DENTIFICATION OF THE VEHICLE

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

100，110，115，120，

102，105，

Max Speed

Km/h

100，105，120

110，125

125

Max Climbing

≥30

Capacity

（50km/h）Brake

≤20

Distance(full load)

Min Turning

≤9

≤9.8

≤10.8

≤9.8

≤10

≤9.8

Diameters(m)

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

condition)

Note：As to the different practical condition, the real fuel consumption will be a little higher than the value

above

4. Main demension

DFSK MINI BUS/SPECIAL BUS

EQ640×

EQ641×

EQ502×

Items

Unit

EQ636××

EQ638××

EQ639××

××

×series

series

Total Length

3640

3795

4040

4070

3905

3795

Total Wide

1560

1635

1560

Total Height

2070，

1925

2105

1950

（Empty load）

2160

Wheel Base

2360

2515

2760

2515

Main Technical Parameter of the Complete Vehicle

FR. Tread

1310

1410

1310

RR. Tread

1310

1410

1310

FR Suspension

555

570

555

RR. Suspension

725

1000

820

725

5. Main Weight Parameters

DFSK MINI BUS/SPECIAL BUS

EQ636

EQ640

EQ639

Items

Unit

EQ641×××

EQ502×××

×××

EQ638×××series

×××

series

Curb

1000,1015,1020，

985,970

1000,1010,1015,1030

1050

1130,1145,1120

1100

Weight

1030

Total

1605，

1400，1415，1595，

1565

1400，1595，1610

1710

1980

Weight

1800

1610

Seating

Capacity

人

2-8

5-8

5-11

2-8

5-7

(Include

Driver)

6. Wheel Alignment Parameters

DFSK MINI BUS/SPECIAL BUS

Items

Unit

EQ636××

EQ638××

EQ640××

EQ641××

EQ639××

EQ502×

×series

××

Main Technical Parameter of the Complete Vehicle

series

Toe-in

0～5

Tire camber

42′±

1°30’

angle

30′

Master pin

9°28′±

(°)

8°

inclination angle

30′

Master pin caster

2°50′±

2°30’

angle

30′

7. Tyre Air Pressure

DFSK MINI BUS MODELS

EQ636×

EQ638×

EQ640×

EQ641×

Item

Unit

EQ639×××

××

EQ502×××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）

load

（175/80R14）

155R13LT）

Rear

tire

Full

250

280(165/70R14)，300

kPa

280(165/70R14)，300（155R13LT）

load

（175/80R14）

（155R13LT）

Main Technical Parameter of the Complete Vehicle

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

4.8

5.3

Lubrication system of engine

3.2

4.2

4.2～4.5

Fuel tank

40，50（Only for EQ6390PF Series）

Lubrication oil of transmission box

1.2

1.3

1.3～1.5

Lubrication oil of rear axle

1.2

Braking oil

0.6

9.A/C System Parameters

DFSK MINI BUS/ SPECIAL BUS

EQ636

EQ638

EQ640

EQ639

EQ502

Items

Unit

××

EQ641×××

××

Series

Cooling Ability

4250

2870

4250

Cooling Wind Speed

M³/h

400

300

400

Main Technical Parameter of the Complete Vehicle

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

℃

Parameter

Protection

High Pressure

MPa

3.2

Protection

Low Pressure

MPa

0.2

Protection

Over-heating

℃

150±5

Protection

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

EQ638×××series include：EQ6380LF；

EQ640×××series include：EQ6400LF；

EQ641×××series include：EQ6410LF；

EQ639×××series include： EQ6390PF22Q；

Main Technical Parameter of the Complete Vehicle

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.

Main Technical Parameter of the Complete Vehicle

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

cabin)

Widened truck

Van

Special truck

Km/

Max Speed

100

100，120

105，125

100，120

100

100，120

100,120

Gradeability

≥30

Braking

distance with

≤20

the speed of

50 km/h

Min turning

≤9.8，≤10.8

≤10

≤9.8

≤10

diameter

Fuel

L/100

consumption

≤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.

Main Technical Parameter of the Complete Vehicle

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)

Note：As to the different practical condition, the real fuel consumption will be a little higher than the value above

4. Main Dimension

DFSK truck and other special vehicle models

EQ1021NF

EQ1021TF × ×

EQ502 × × ×

EQ502××××

EQ1021GF24Q

Item

Unit

EQ1020TF

Truck (Double

×××

××

Truck

cabin)

Widened truck

Van

Special truck

Truck

4390，4150，

3795，4070，

3795，4150，

Length

3980，4160, 4410

4538

4335，4220，4150

4280

3980，

4040

4185，4220

Width

1560

1635

1560

Height (zero

1825

1860

1890

1925，2105

2150

2160，2490

1850

load)

Main Technical Parameter of the Complete Vehicle

Wheelbase

2515，2760

2760

2515

2760

Front tread

1310

1415

1310

Rear Tread

1310

1410

1310

555/1080

Front

555/725，

，

555/910，

555/725，

555/1265

suspension/

555/1080，

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

2290×

×1440，1430，

×1330，1400，

940

×1440× 340,430

350

carriage

1440，

1400×1350

1440×340，430

340

5. Main weight parameter

DFSK truck and other special vehicle models

Item

Unit

EQ1020TF

EQ1021NF

EQ1021TF×××

EQ1021GF24Q7

Truck

Truck with double cabin

Widened truck

Truck

Curb weight

910，900，880

965，1030

990

970

Total weight

1810，1530

1780 ，1845

1920

1700

Passenger

capacity/

2/790,2/800

人/kg

2+3/490 ，2+3/490

2/800

2/600

2/490

capacity

Main Technical Parameter of the Complete Vehicle

6. Wheel Alignment parameter

DFSK truck and other special vehicle models

Item

Unit

EQ1020TF

EQ1021NF

EQ1021TF×××

EQ1021GF24Q7

Truck

Truck with double cabin

Widened truck

Truck

Toe-in

0～5

Tire camber

1°30’

42′±30′

1°30’

angle

Master pin

inclination

9°28′±30′

（°）

angle

Master pin

2°30’

2°50′±30′

2°30’

caster angle

7. Tire air pressure

DFSK truck and other special vehicle models

EQ1020T

EQ1021NF

EQ1021TF × ×

EQ502××

EQ502 × ×

Item

Unit

EQ1021GF24Q7

Truck (Double

××××

Truck

cabin)

Widened truck

Van

Special truck

Zero

180（165/70R14）

kPa

20（165/70R14，155R13LT）

200（185R14LT）

200（165/70R14，155R13LT）

Front

load

200（165R13LT，155R13LT）

tire

Full

220（165/70R14）

kPa

24（165/70R14，155R13LT）

220（185R14LT）

240（165/70R14，155R13LT）

load

240（165R13LT，155R13LT）

Zero

200（165/70R14）

kPa

24（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）

Main Technical Parameter of the Complete Vehicle

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

4.8

5.3

engine

Lubrication

3.2

4.2

4.2～4.5

system of engine

Fuel tank

Lubrication oil of

1.2

1.3

1.3～1.5

transmission box

Lubrication oil of

1.2

rear axle

Braking oil

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.

Main Technical Parameter of the Complete Vehicle

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,

This vehicle is with two keys,

and the locking button shall be pressed

Inside the Vehicle：

please keep one in a safe place for

down while driving to avoid any

spare use.The other can be used for

All the doors can be locked by

unexpected open of the door.

ignition switch, front door and back

pressing down the locked button. After

Back door：

door.

Please keep the key along with you

that, the door can not be open either

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

then turn the key clockwisedly. While

open it, pull the locked button upward.

open the door, turn the key

Front Door：

counter-clockwisedly and open the

The front door can be open and locked

door.

by key. The locking button rises while

2. Key

open, and is down while locked.

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

Main Technical Parameter of the Complete Vehicle

on the inner side of the door. Turn the

handlebar

clockwise

counter-clockwise, the door window

will come up or come down.

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.

Pull up the button, the window will be

Switch 2 is for use of the window in

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 fixing of the front row seat is

the co-pilot’s side.

Rear Door window

just like the picture below, make the

Main Technical Parameter of the Complete Vehicle

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

to the middle-row seat.

place as required; pull up the backrest

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

There is a stopper for the rear

No adjustment to the seat is

the seat will be locked.

allowed during the driving, or else, the

row seat, pull out the stopper, and

seat may move abruptly forward or

Folding Seat

backrest can be put horizonally, after

backward which may cause the

driving out of control.

than, loose the stopper handle; while

open, turn the backrest to the final

position, the stopped will be locked

Main Technical Parameter of the Complete Vehicle

requirements.While undo the safety

automatically.

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

“clatter” sound.

seat, turn on the latch, the seat can be

The length adjustment of the saftety

turned over

90° forwardly so as to

belt is very important. While adjusting

As low as buttock

the lap belt, please check the lock at

loading or discharging goods. The

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

different

The safety belt is designed according

Main Technical Parameter of the Complete Vehicle

to the human body skeleton, (See the

Safety belt should be prevented from

Do not use the deformed saferty belt.

polishing compound, grease spot, chemical

picture). Please note that, the waise

One safety belt is only for one person,

article, especially storage battery sour liquid

band part shall not be across the

tie the children on knee of passenger

polluted. While washing, you can use

abdomen.

to the safety bealt is very dangerous.

neutral soap and water. If the safety belt is

The adjustment of the safety belt is not

The position of lock limit position

worn and torn, polluted or damaged, should

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,

it should be changed.

function.

Main Technical Parameter of the Complete Vehicle

8. Dashboard

14 Emergency Switch

9、Side Intake

8. Dashboard（One and half of cabin）

①Assembled Meter

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

11 Centre Intake

converting switch

1. ‘Off’: the auxiliary equipments don’t

12 Side Intake

4、Head lamp control switch

work, only head lamp and horn work,

13 Tool Box

5、Rear Foglam

and the key can be pull out only in this

position.

6、Rear Foglam

2. ‘ACC’: assisitant equipments

7、Cigarette Lighter

(radio & cigar lighter) work and the

engine don’t work.

8、Auxiliary Frame Air Bag

3. ‘On’: while at this position, all

Main Technical Parameter of the Complete Vehicle

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

of the steering pole, the operation is as

engine cannot be started, please wait

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

Main Technical Parameter of the Complete Vehicle

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.

Note:

There are four gears

When it frozeon the glass should

Press down the button, all the four

the ice and snow be cleaned first and

INT：Intermission gear, whichis

turning lights and the side turning lights

connect to the defost device, then start

used when foggy and sprinkle

the wiper.

glitter simultaneously. Press the other

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

Main Technical Parameter of the Complete Vehicle

Press down the button, all the four

The horn button is on the wheel

turning lights and the side turning

Press the emergency light, all the

lights glitter simultaneously. Press the

panel

four turning lights and sideway

other end will turn off the lights.

① if it is a TOM’ style wheel

This switch is only used for

turning lights will flash at the

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

abnormal

sides of straight range .

condition, use this switch.

14. Emergency light switch

Front Foglight:

Turn the headlight switch to the

Main Technical Parameter of the Complete Vehicle

the indicator light.

second gear, and press the foglight

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）

Vehicle Devicesxs and Mechanics Operation

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

vehicle too dirty and the windpane

& Outside

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

Control the tempreture of cold &

meter board or through side

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.

form from the aforesaid ①-⑤ gas

the meter board or through side

④ Defrost & Warm Air

vent. This button can choose the warm

ventilation.

Warm air is sent off from the exhaust

air form from the aforesaid ①-⑤

② Sending off Wind in both

port on the floor, some is sent off from

Vehicle Devicesxs and Mechanics Operation

Control the rotate speed of fan, that is ,

directions: Cold air is sent off from the

windscreen and side defrost exhaust

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

be too long while the air is in inner

Control the circulation of the air of

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.

warm air (blue is cold air, and red is

exhaust port on the floor, some is sent

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

Odometer

This is just for reference

① Speedometer

18. Assembled Meter

② Odometer

Vehicle Devicesxs and Mechanics Operation

18.

Assembled Meter（One and half

The speedometer expresses with km/h

the speed of the automobile.

cabin）

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）

③ Left & Right turning indicator

Odometer after finishing caculation ,

light

① Speedometer

count again since " 0 " , analogize

sequentially to count for the first time.

④ Fuel Gauge

② Left & Right turning indicator

Note:

⑤ Water Thermometer

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

Vehicle Devicesxs and Mechanics Operation

in all to show the total driving mileage,

18.

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

the mileage of short distance of

图 1

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

Vehicle Devicesxs and Mechanics Operation

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

indicator light turns on; turning right,

1 unit as 1000rpm.

While driving, the water

the right indicator light turns on.

18. Assembled Meter

tempreture should be kept in the

18. Assembled Meter

normal scope, that is: between ‘C’&

Vehicle Devicesxs and Mechanics Operation

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.

Vehicle Devicesxs and Mechanics Operation

18. Assembled Meter

Note

It shows the brake system

Note:

breaks down when the ignition

At this situation,

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.

this indicator light will be on and will

be out after adding brake liquid

Otherwise please trailer it to the

be out after the safety button inserting

maintenance stop.

according to the regulation.

into the safety belt fixing housing

18. Assembled Meter

which shows the safety belt has been

well buttoned.

18. Assembled Meter

Vehicle Devicesxs and Mechanics Operation

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

19. Cigar Lighter

unreleased, the parking brake light

pulled out, while clearing up the

will be on.

cigarette ash, push it downwards, then

totally pull out from the socket

18. Assembled Meter

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

several seconds and the resistance

position of ‘ON’, the trouble lamp will

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

Vehicle Devicesxs and Mechanics Operation

（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

（2）On-Off/ Sound Effect Knob

（The picture is just for reference）

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

Rear View Mirror

21. MP3& Radio（One and

（10）AS/PS Knob

half of cabin）

（11）AUX

Vehicle Devicesxs and Mechanics Operation

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.

Vehicle Devicesxs and Mechanics Operation

that you can see the behind vehicles or

24. Interior Top Lamp

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

26. Sunshading Board

Do not hang anything on the handgrip

the top of middle row and rear row of

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

adjusting, place hands close to both

accident.

ON means open; Put thebutton in the

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

Vehicle Devicesxs and Mechanics Operation

① Tool Bag

② Plier

③ Hatch Spanner12×14

4 Screwdriver

5 Handlebar of Screwdriver

Draw up the brake rod, the vehicle

Clutch Pedal

6 Handlebar of Sleeve

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

push the button on the top of the brake

9 Crank of Jack

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

Note:

for

each,

and

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,

to check the placement of the jack and

al condition such as cold, humidity,

please put the shelf in the low-grade or

jack crank.

ice and snow etc. will cause the brake

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

loudly, please check the brake system.

30. Pedal

Accelerator Pedal：

The rotating speed is controlled by

accelerator pedal, step down the

Vehicle Devicesxs and Mechanics Operation

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

1^st gear: first pull towards to left and

lies

then push forward.

2^nd gear: first pull towards to left and

ng,

then pull backward

and

3^rd gear: push forwards in the central

ont

position

cover, then prop up storehouse cover

4^th gear: push backwards in the central

with struts.

Note:

position

Do not change the gearlever

5^th gear: pull towards right first and

from 5^th gear into reverse gear.

then push backward

Please first push the gearlever to

neutral and then change into

reverse gear.

Vehicle Devicesxs and Mechanics Operation

The first

1.Running-in

Gear

2500

In the course of car running-in, we use

Note:

kilometers

the best material, every part is

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

starting system to be damaged. Do not

Gear 3

40Km/h

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).

2. Start of the Engine

the general principle that should be

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

Start the Engine

3. While in the course of running-in,

is in the position of neutral.

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.

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

normal, and then repeat the above

damage the clutch.

trying several times, the engine might

While driving the vehicle, drivers

course.

Please check at first

should frequently observe the

happen with “flood the jar “which

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

pedal and try again to start the engine

shorten the life-span of the engine and

clutch to try again, after putting to

hinder changing the gear steadily. The

(then the ECU will control fuel

drive is along with synchronization

gear, let go of brake pole, meanwhile,

injector cutting off oil supply). Five

test machine which make the gearshift

easy and without noise. A good

step on throttle slowly, when step on

seconds later, the high-speed air

gearshift would enable rotational

the clutch, listen to the voice of the

current blow down the overflow oil

speed of the engine remain throughout

in a certain range, and no matter how

and then let go of gas pedal and can

engine, with the gradual release of the

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

regard the footboard as a stop for a

brake parking point in order to

ON ", if failed, please wait for five to

decelerate gradually.

rest, or don't half step on clutch while

ten seconds or wait fifteen seconds

Step on down brake pedal, the front

Guide for Vehicle Operation

and rear brake will work at the same

lower the fuel consumption:

time. If there are shrieks some times

①Avoid running idle for a long time:

while braking, it is because of

humidity of the road surface or cold

If you don’t drive the vehicle after

and snow weather etc. So it is a

waiting more than one minute, you

normal.

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

②Avoid Emergency Brake: it is a

Station of Dongfeng YUAN.

helping system; it can make the brake

Don't apply the brake in succession

waste of energy for braking and also

more stable. Do not step on the brake

for a long time, or put the foot on

pedal to-and-fro while applying the

recovering driving speed will consume

the brake pedal while running for a

brake. When the vacuum helping

rest which will cause the brake to

the fuel.

system lose efficiency, the energy

lose efficiency for overheating or

stored will gradually subside effort in

③Keep the invariable speed: Keep

the braking distance too long or

brake pedal with applying the brake

will cause the permanent damage

the invariable speed in the allowed

each time.

of the brake.

road and traffic condition.

Note:

ithout the vacuum helping system,

④Keep the loading capacity

Note:

Eit will need more footboard stren

gth

minimum limi

After water enters the brake drum, it

e brake and

Ewhilemapplyinginth

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.

when the tire pressure is insufficiency,

So after the vehicle paddles or being

washed, you should lightly step on the

brake pedal intermissively at a much

low speed, operate the brake

repeatedly, and dehumidify brake until

Guide for Vehicle Operation

Driving on the icy road

low gear promptly according to the

the resistance for driving will increase

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

icy road.

overloads or being damaged. Pay

then the tire should be pumped

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.

low gear while climbing the slope in

Start, accelerate or when driving a

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

① Vehicle should be put into

Avoid the operation of the steering

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

brake the vehicle by taking advantage

change direction.

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

② Try not to make the rotational

running with neutral; it will still

following points:

consume the fuel instead of saving

Assemble the vehicle according to the

speed very high.

fuel.

Instruction

Manual

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

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.

Guide for Vehicle Operation

damaged, and method of adjusting and

1.Fuel

about 6-9mm and assure there is no

changing of the belt are as follows:

any damage to the belt. If the belt

1. Unclamp the three setscrews of the

generator.

needs replacement or adjustment, pls

2. While wanting to stretch the strap,

go to the authorized service center of

unscrew and draw outwards the

generator, fix the generator when the

DFM mini auto for maintenance.

strength

of the

belt

reaches

4. Engine Oil

above-mentioned criterion.

Engine Oil Trademark

3. While changing the strap, unscrew

The oil shall be No. 93 high-quality

Use 15W/40SP while the tempreture is

and make the generator slip and move

unleaded gas. The capacity of fuel

above

15°in summer; and use

inwards, Tighten the strap according

tank of this vehicle is 40 liters; Refuel

10W/30SF (GB11121) while the

to the regulation of 2 after changing

access cap lies in the right below part

tempreture is below 15°in winter.

the strap.

of center pillar. Open up the the cover

3. Compressor Belt

by key and turn counterclockwise, and

Note:

then turn the key clockwise to cover it

MeasChange the engine oil while the,

tightly.

erunning-inoof lthel new gasoline

2. Generator Strap

svehicler isit2500KMityandteafter

enormal driving for 5000KM.ne use

and maintain the manual.

While exerting the strength of about

98 Newton (strength of 10 kilograms)

to the adhesive tape of the fan between

4. Engine Oil

The vehicle with A/C is

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

Check/Maintenance Service

petrol machine use and maintain the

manual.

5. Engine Belt

7. Thermostat

Note:

In order to make oil filter fasten

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

or the washer cover is damaged.

the engine oil filter by turning

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

instruction manual of the gaslion

rubber washer of the engine oil strain

Note:

machine of DELPHI system or unite

The vehicles must be parking on

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

petrol machine use and maintain the

the coolant.

the installing surface.And then twist

manual.

Add, change and infuse coolant

the strain engine oil to 3/4 of the

Gasoline

Filter&Oil

Refer to the service maintainance

Supply Tube& Oil Return

circles by strain spanners.

instruction manual of the gaslion

machine of DELPHI system or unite

Tube

electricity systematic electricjet serial

Check/Maintenance Service

There is 0.3MPa in the oil supply

The filter element of the air cleaner

system. While changing gasoline filter and

should be often removed and washed.

The spark plug is F6TC (4C7T) and

oil supply tube and oil return tube and tie-in,

Wash once when running 10000KM

the whorl is M14 *1. 25.

on the pitch road, wash once each time

you should adopt the right fittings from

When there is accumulated charcoal in

while running 2500 kilometers at dirt

Dongfeng YUAN. You had better go to

road.

the plug, it is difficult to produce

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

instruction manual of the electric jet

hidden danger.

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

Check/Maintenance Service

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:

causWhile installing the spark pl

present, the vehicle, while parking for

of the sensor located in air throttle and

ug, please

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

Check/Maintenance Service

which should be adjusted.

of exhaust from engine; three-way

18.ABS

convertor can reduce the harmful gas

ABS (Antilock Braking System, ABS

effectively.

for short) can prevent wheel from

braking completely suddenly by

automatically and repeatedly adjusting

It is quite easy for three-way convertor

the braking pressure and fully utilize

to be overheated while the gasolines

peak value of the adhesion coefficient

engine working, and which may cause

among the tire and ground and high

the damage of the three-way convertor.

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.

the brake promptly to gain the

while the driver is in the course of

The idle stroke of steering wheel

manipulation of the automobile while

operating, please refer to instruction &

along the circumference is 0-30mm.

applying the brake and the direction

maintainance manual of gasoline

The turning of the steering wheel

stability, and there is integrated

engine of DELPHI system or unite

should be light and smooth and

control system of electromechanics

electricity systematic electricjet serial

without noise.

combined by shortest braking distance

petrol machine use and maintain the

17. Clutch Pedal

advanced electronic technology and

manual.

mechanical technology.

15. Electric Fuel Pump

The work of ABS systemis automatic,

The fuel-pump is in the fuel tank.

whenever, as long as the apperceive

Note:

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,

Check/Maintenance Service

On decorating road, the braking

stepping on the brake pedal by 294N

Note:

distance of vehicle with ordinary

(30kg)

When ABS loses its function, the

braking system will be shorter than

performance of brake system is same

that of vehicle with ABS.

with that of the common brak system.

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

⑥ The pedal bounced while stepping

Note:

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

When stepping the brake pedal down

distance of vehicle with ABS is longer

Note:

check if the rear wheel stopped , and

completely, the distance ‘A’ between

than that of vehicle without ABS but

check when draw the hand brake rod

Do not mix the different kinds of and

the pedal and the front wall shall not

with common braking system. If the

upwards by strength of 20kg, if the

different types of brake liquid

less than 95mm. And it should be

vehicles with ABS system please

pole stops in (3-8) ratches.And it shall

together, otherwise which may cause

checked and maintained if the

reserve longer brake distances.

the serious damage of the braking

also be checked that when relax hand

following things happan while

system. Do not utilize the old, used or

unsealed brake liquid.

Check/Maintenance Service

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

the flower stria to make certain that if

transposition when it is running every

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

wearing and tearing, crack and

scutcheon on the driver’s side door).

When the air pressure is too low, it

damage for the tire. If yes, please

will cause the tire worn and torn too

change it.

much and difficult to drive and heavy

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

embed in the flower stria.

165/70R14, and the pressure should be

the middle of the tire will be badly

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

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

should be the same.

slowly pump the tyre and at 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

While replacing the tyres, the four

The following check should be carried

condition.

tyres shall be the same type.

out in the course of using:

In order to prevent tire from being

Note:

The spare wheel shall be the yellow

steel wheel which can be only used

when emergency.

Taking the spare wheel as the

Check/Maintenance Service

the connection end and erosion will

cause poor contact. If the the white

power is found at the connection end,

it should be clean up and then spread

20.

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

carried out counter-clockwise to make

① Take off the jack, tool and spare

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

①Major Fuse: Bear the

the nut.

electric current in the battery directly.

③ Put the jack in a proper position

When it is burnt, no electric

and raise it up.

component can work normally. If so,

④Discharge the wheel.

please check the circuit of the

④ Fix the wheel and change the nut.

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

Check/Maintenance Service

Note

22. Fuse

Note

If the major fuse is burnt,

In order to guarantee that

the users should replace it

Note

there are spare fuse for

instead of using the wire etc as

If the electric machine works

replacement, three 10amp and

substitute which may cause the

without cleaning liquid, it will

15amp fuses will be prepared in

damage of the electric system,

cause damage. Do not use he

the fuse box.

even the fire.

ngine ntifreeze instead of

①Fuse 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

Liquid

Please replace the bulb when it cools

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

and cause fire, please wait till it cools

Note

down and take it off by wrapping it

Users should use the right capacity

with soft cloth.

fuse while changing the burnt fuse,

If the bulb is frequently burnt, it shows

using the aluminum foil or aluminum

that there are some problems with the

wire and other substitutions are not

Check the container for cleaning

circuit. Please go the Dongfeng Mini

allowed. If the fuse is burnt in a very

liquid, if there are not enough cleaning

Auto Maintainance Station for help.

short time, it shows there are big

liquid, please add it

problems with the electric, please go

to Dongfeng Mini Auto Maintainance

Station for help.

Check/Maintenance Service

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

⑥Contrarotate the fender light or

Turning Lights, Side Turning Lights,

Rear Assembled Lights, Liscence

tailstock of the turning lights and then

Lights.

removes the bulbs for replacement.

There are two forms of bulbs (ellipse

24. Replacement of Bulb

or roundness), and the ellipse bulb can

Check/Maintenance Service

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 "

way carry on circuit is it check to set

25. ECU

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

be kept in the cover board of the front

washing

headlight bulb

storehouse. After using, please return

⑥Contrarotate the fender light or

25. ECU

to the storehouse and make sure they

Check/Maintenance Service

And any person shall not be under

yellow is pressuer over high, red over

have been fixed up firmly

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

Take out the extinguisher and pull

light

the cover then spurt extinguishing

Lock up the parking brake, and put

agent in 1.5M distance of root of fire.

Pressure extinguisher valve until

gearshift rod in the reverse gear, and

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

Please refer to the Instruction

Every

2 years change

position and upright jack up the

extinguisher with 450g, and every 4

Manual for the operation guide of

years change extinguisher with 500g,

vehicle steadily and slowly to the

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.

checked in appointed factory per year.

If the jack begins to incline, please

30. Operating controller

4．Check the index during green

correct it to the right position.

Jackup on the slope is not allowed.

area or not for 500g extinguisher with

pressure gauge. Green is natural and

Check/Maintenance Service

Press UP botton, and keep the normal

speed. When trun over to some angle,

31 .Trurning Over and Side

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

①Open lift switch to ON

motor and buzzer beging working,

① Take out the controller from cabin.

people apart from cargo box.

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

蜂鸣器开关

Check/Maintenance Service

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

shaft pin downward so that to separate

Right turn

from the side plate lock, then open the

① Put single bolt into right single

box side plate.

groove when turn the cargo box to

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.

When cargo box in normal location,

②Then operate as above ②③ in

rear plate can not be closed

turn over operation.

automatically, should with manual.

operation of rear plate of cargo box

Press the hand shank of rear plate

Rear plate of cargo box be open

starting connecting rod, make the box

②Then operate as above ②③ in

automatically when the cargo box turn

rear plate back to the hinge match

to some angle. Mainly because the

turn over operation.

position, then loosen the hand shank,

movement relationship

between

operationg of equip stay bar.

make the latch hook and hinge shaft

system of rear plate starting

Use the stay bar when turning to some

pin fit then the box rear plate will be

connecting rod and the starting of box

angle without loading, adjust the flip

closed.

rear side-plate back plate. Rear plate

angle, to ensure the top of stay bar in

operation of side plate of cargo box

starting connecting rod system is

its safety area, achieve the purpose of

Check/Maintenance Service

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

replace or charge the battery, or

been full discharge, only use for

box.

inform the repair plant

checking and maintaining cargo box.

nominated by the factory. And a

triangle plate should be placed

Note for operation of lift

around the box to warn the

Note： nitial use, the vehicle should be

passers-by. No manual operation

loaded in accordance with the initial

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

Notice： the vehicle could not

should be in horizontal position to

exceed 10km/h when the cargo

avoid the accident of over flip.

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

Check/Maintenance Service

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

box；

Rated wattage of the hydraulic

Notice： Unauthorized

type of lubricant and the

motor：800W; Rated rpm：

personnel must not use and

interval between two refills：

4000r； Rated voltage：12V；

operate the power switch of the

The lubricant should be made

Rated current：67A。

dumper truck；

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

Dump systems hydraulic oil: model

0.625；

HM 46: HM hydraulic oil developed

-10˚C-40˚C。

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,

low alkaline zinc, zinc and ash-free

the manufacturer should be

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:}

Check/Maintenance Service

recommended by the manufacturer or

l）To maintain the cleanliness of hydraulic

（3）Storage and use, fuel containers and

the product supply applies to the pump

systems, shou be the timely removal the

tools must be clean to prevent oil

sludge and metal shavings of the fuel tank.

load limits.

contamination

Note: After

5000Km drived, filter

（2）Reference indicators to change oil,

（4）The oil is mainly used in steel -

should be changed.

all the equipment parts should be cleaned to

steel pairs of hydraulic

prevent impurities mixing into oil and

pumps. Friction material for other

affected

hydraulic pump, the pump must be

Ⅵ . Check & Maintenance Service

Check/Maintenance Service

Period

Km×1000

moon count as standard confirm

1. Daliy inspection

Failure

maintain time form. Every inspection ,

Daliy inspection is a necessary

3Fuel Level

adjust

, lubricate should stipulated

work for driver. The conditions of the

14Door Lock

time go on according to form strictly

vehicle changes every day, so please

with other maintenance work.

15Rear Mirror

check it before driving, which can

Note

16Licence Plate

The maintence items with mark

help find the problems and solve them

2 、 Regular Check and

‘*’ should be carried out by the

before driving to enable to be safe.

Maintainance

special maintainer. While regarding

1 Fan belt

to items without

‘*’ can be do

3、Regular Maintainance Perid

2 Engine oil

maintenance according to the

and Items

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

problems while checking and take

5 Engine Coolant

Yuan.

measures accordingly. The running

6 Stroke of Brake Pedal

kilometers and months will be the

7 Tire

standard maintenance time. The check ,

4 、 Signs for Regular

adjustment, lubricant and other

8 Free way of Clutch Pedal

maintenance service should be strictly

Maintenance

9 Turning Operation

subject to the stipulated time in the

‘G’ means change

10Indicator Light & Indicator

form.Make form recommend several

‘R’ means needing to be lubriacant.

Meter

project of checking emphatically,

‘X’ means screw to the regulated

through is it pinpoint the problems to

torque.

1Lighting System

check , take the pertinence measure in

‘J’ means checking.

12 Instruction of Electric Jet

time. With go kilometer count or

‘T’ means adjustment.

Check/Maintenance Service

Months

Engine

1.Fa（Water Pump、 Compressor）

Drive Branch Belt （ Strain 、

Abrasion ）

*2.

Camshfte Synchronization

J.T.G

Tooth Belt(Strain, abrasion, damage)

*3. Valve Gap

J.T.

*4. Engine Bolt(cylinder cover,

manifold toggle)

5. Oil fillter

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

Colling System(leaking ,damaging

etc.)

*9. exhaust system

J.T.G

5、Maintenance

Periods

Km×100

Items

month

Ignition

*10.

J.T.G

Ignition Coil(damamged, deformed)

*11. Spark Plug

*12.Ignition Timing

J.T.

Check/Maintenance Service

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

*15 Fuel Cleaner

Exhaust Control of Crankcase

*16. Exhaust Soft Pipe & Tie-in

J.T.G

*17.

J.T.G

Fuel Steam Storing Device

*18. PCV Valve

J.T.G

Periods

Km×100

Items

monthes

Electric Equipment

*19. Electric Wiring, Connect & Lamps

J.T.G

Chassis & Body

*20Clutch

J.T.

*21.

Brake

Fluid(Liquid

J.T.G

Mass,Leaking)

*22.Brake Pedal(Stroke)

J.T.G

*23. Manual Brake Rod &

J.T.

Check/Maintenance Service

Cable

*24. front: Brake disk & cliper

J.T.G

*25. Rear: Brake Drum &

J.T.G

Brake Shoes

*26. Brake Soft Pipe &

J.T.G

Pipeline(Leakage, damage)

27. Tire(Abnormal Abrasion,

J.T.G

Abnormal Air Pressure)

28. Wheel & Boss Nut

J.T.G

Check/Maintenance Service

Periods

Km×1000

Items

monthes

*29.Bolt & Nut(Elasiticity)

*30.

Steering

Wheel(Gap,

J.T.G

Elasiticity)

Cooling System

*31. Refrigerant

*32.Brake System

J.T.

J.T.G

J.T.

J.T.G

*33.Compressor

*34Condensor

Check at any time

*35.Evaporator

J.T.

*36. Desiccator

*37. Refrigerate Pipeline

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

3. Malfunction of Transmission

Problems

Reasons

Solutions

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.

Emergency Measurement

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

Emergency Measurement

5. Malfunction of Steering System, Suspension System, Wheel and Tyre System

Problems

Reasons

Solutions

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

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

Emergency Measurement

cooling air output off and

Failur of the connection of the circuit

Repair when necessary

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

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

Emergency Measurement

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

Emergency Measurement

Oil or fluid leak

Sealing of the axle is damaged

Replace

O ring damaged

Replace

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)

Emergency Measurement

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)

Emergency Measurement

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

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

Emergency Measurement

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

Emergency Measurement

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

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

° C,

° F

environment)

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.

Emergency Measurement

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

2）Check sensor damage or whether there exists

a foreign body, to see if it is in good working

condition.

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?

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?

Emergency Measurement

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

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?

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?

Emergency Measurement

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.

1）Disconnect the ignition switch

With

"R", "R / W", "B1", "B1 / W", "Y", or "Y

well-known ABS

/ W" circuit is open, poor contact or

2 ） Connect the connectors to the ABS

control

module

short-circuited.

hydraulic unit.

replaced

and

3）Measure the ground resistance of module

re-check

terminal A1, A2, A7, A8, B12 or B13, to see

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

Emergency Measurement

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

Problem

Reason

Treatment

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

Problem

Reason

Treatment

Emergency Measurement

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

Problem

Reason

Treatment

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

Emergency Measurement

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

Emergency Measurement

poor connecting of wiring end. After

not bend over the battery.

respectively. Pay attention that the

Confirmation, charge the storage

cable shall not be near to the belt

②Do not expose the battery to direct

battery or repair the connect point.

pulley, belt or fan.

fire or make it under the spark.

③Start the engine of the vehicle with

③Keep your eyes & skin away from

②If the headlight keeps being on,

battery first, then start the engine of

the storage battery acid. If any part of

the vehicle without electricity.

the skin touches and holds the acid

please check the fuse. If there are still

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

Please follow the following

If battery is installed again

YUAN Auto for repair.

after being removed, the original

2. Instruction of Storage Battery

instruction while parallelizing the

designed condition will lose in

Connect Start

ECUand you may find the idle

battery to start:

If the engine can not start because of

speed is too high or too low

①Put one good 12V storage battery

the storage battery, you can connect

when re-starting this is not a

close to vehicle, and make the link

oNotend storage battery in parallel or

trouble and it is unnecessary to

cable reach to the storage battery.

storagStorage battery can produceing

adjust, the ecu will adjust the idle

Make the two vehicles close to each

inexplosive gas, and the causticitygh

speed to the regulated value after

and the big output

other but not touch each other while

elacid in which

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

cathode of the corresponding battery

engine will temporarilygoo beyond. If

①Make you eyes protected, and do

Emergency Measurement

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

infuse coolant to store liquid barrel

the value of the water thermometer

Traction of the Vehicle

go down to the safe range.

and then to the radiator carefully if

If need traction, please send for

③If the tempreture of the water still

professionalist or special maintainer of

does not go down, please check the

necessary.

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

yes, wait till it stops.

your vehicle in the vehicle

traction, please adopt the

water tank, if its location is lower than

correct equipment and steps

" LOW " line, please look for the leak

Traction of the Vehicle

while traction.

Don't adopt the way in which

point in water pump , radiator and

the rear wheel land while

drawing otherwise may cause

water pipe junction, if position of

the damage of the gear box.

100

Emergency Measurement

firmly by special lock framework.

Note

If you use the front traction euippment

WhUnless emergency, do not tow the, the

to tow from the front part, the rear

vehicle by transporting pothook

wheel shall be fixed to a moveable

generally.heels land and the rear

platform. There are transporting

wheel.lifted. Put the ignition switch on

pothook at front and rear end, which

is only use for transportation.

‘ACC’ position to unlock the steering

wheel, the front wheel faces just in the

front. The steering wheel is locked up

101

Vehicle Protection

1. Cleanness of the Vehicle Inside

water & neutral soap from ethylene

③The scratch of the body

Vinyl Plastics

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

④The dirt will corrode the car

water. Spread the liquor to the vinyl

in the shady and cool place.

body. So the more important thing is

plastics; make the dirt soften by

that your car should be kept clean,

soaking several minutes. Polish the

Note

without dirt always, and keeps the

internal and external surface of car

Do not use varnish thinner,

cover paint in good condition to

thus to remove the dirt and soap with

petrol such volatility solvent or

protect the body from being corroded.

the clean warm cloth. If there is dirt

such materials as bleaching agent,

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,

①Wash the bottom of car body

will cause the bodily injury or the

wipe the dirty place with the clean

in order to remove the mud and grit

vehicle to damage by improperly

cloth soaked with the gentle soap

with the high-pressure water. Make

use.

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

The dirt or any other things on

You can use the sponge stained with

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

problems as time goes on.

don't be used or it may scratched and

the intensity of the safety belt decrease.

replied the hard material which covers

①Cover paint Fades

Cleaning of the Floor

the paint.

②The degradate lacquer film

Usually the filth can be cleaned up by

③Wash the outer part of the vehicle

causes the car body to get rusty.

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 ,

sour

, salt ,etc., which should be

④Once after the dirt is removed

vehicle waxed & polished after

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

overflowing,

please

clean

⑤After washing, clean the car

①Only wax and polishing

immediately.

body gently with the wet cloth, and

compound with high quality can be

d. Don't park your automobile in

dry it in the shady and cool place by

used.

air.

②While using wax and polishing

the car moistly, poor ventilation place,

compound, please pay attention to

and don't wash the automobile in the

⑥Check the spray paint surface

following proceedings that the manufacturer

garage.

to see if there are damages needing to

stipulates.

e. Don’t spread the primer and

be repaired.

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.

Vehicle’s Outer Part

a. Clear up all damaged part and

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.

Copywright Reserved

silt under the mat of the auto room can

While using the cleaning agent, the

accelerate the corrosion of the vehicle.

After washing, please check

following precautions of manufacturer's

So, please keep the vehicle clean.

whether there are water entering

regulation should be paid attention to.

the brake or not. If yes, please

c. When loading and unload

Don't use strong house using detergent

stepped on the brake repeatedly

or soap.

104

and slowly to dehumidify it

during driving a vehicle at a

low speed.