Preface

Thank you for using Dongfeng Brand mini truck. Dongfeng Mini Truck is the new generation product manufactured by Dongfeng Vehicle Co.,Ltd., safety, reliable, comfort driving and high performance. For better operation and maintenance the products, the operation manual is carried out. The book introduces the driving operation, maintenance, assembly and regulation, malfunction analysis etc,. Please read it carefully before operation, master the operation method quickly, maintenance and repair the vehicle regularly according to the suggestion to ensure the security of truck, prolong the operation life of vehicle. With the development of technological progress, Dongfeng Mini Truck makes improvement and perfection, and it may occur different between the Operation Manual Introduction with the actual structure of vehicle, if any different, we will amend. Dongfeng Vehicle Co., Ltd. October, 2011
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Statement
Dongfeng Vehicle Co., Ltd. will not responsible for the reliability, security and adaptability of the vehicle if the following condition occurs: 1. Without permission, customer changes or modifies the design of machine; 2. Original spare parts, approved convertible parts or components instead by other parts; 3. Over loading during the operation. Symbol stipulated in the manual as follows: Note: It may cause personal injury or the damage for the parts and the vehicle if do not comply with and pay attention to the matter which symbol stipulated. Warning: It may cause serious personal injury or great property loss if do not comply with the matters which Warning stipulated.

Content
Overview of Vehicle .......................................................................................................................................... 5 Main Parameters ............................................................................................................................................... 6 1. Fuel ........................................................................................................................................................... 6 2. Location of Nameplate, VIN and Engine Number .............................................................................. 6 3. Vehicle Technical Parameters (Model EQ1040GLJ4-CMD1-D)....................................................... 7 Operations.......................................................................................................................................................... 8 1. Various devices and mechanism operations....................................................................................... 8 2 Vehicle use ................................................................................................................................................. 31 Maintenance and Inspection ......................................................................................................................... 37 1. Regularly safety precautions of routine maintenance ..................................................................... 38 2. Routine maintenance............................................................................................................................ 39 3. Periodic Maintenance ........................................................................................................................... 39 Malfunction Analysis and Elimination ............................................................................................................. 53 1. Malfunction of Engine System (Please refer to Engine Operating Instruction Manual) ............. 53 2. Malfunction of Clutch System.............................................................................................................. 53 3. Malfunction of Gearbox System .......................................................................................................... 55 4. Malfunction of Compensating Gear System ..................................................................................... 56 5. Malfunction of Steering mechanism, Suspension, Wheel and Tire System ................................. 57
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6. Malfunction of Braking System ........................................................................................................... 60 7. Malfunction of Power Supply System ................................................................................................ 62 8. All sorts of light fitting malfunction ...................................................................................................... 63 9. Accessories malfunction ...................................................................................................................... 66 Emergency Treatments .................................................................................................................................. 67 1. Tire replacement ................................................................................................................................... 67 2. Bridge connection starting ................................................................................................................... 68 3. Engine overheat .................................................................................................................................... 69 Body Maintenance .......................................................................................................................................... 71 1. Measures of protection ......................................................................................................................... 71 2. Vehicle interior cleaning ....................................................................................................................... 72 3. Body cleaning ........................................................................................................................................ 72 Fuel and Lubricating Oil, Vehicle Mounted Tools ....................................................................................... 74 1. Fuel/lubricating oil/coolant/scrubbing solution .................................................................................. 74 2. Vehicle mounted tools list .................................................................................................................... 75

 Overview of Vehicle

Dongfeng mini truck is a new developed and designed product of Dongfeng Vehicle Co., Ltd. The truck is the most ideal tool for short distance transporting in modern city and countryside with right hand steering wheel and hydraulic braking truck. Unique outlooknovel modeling, flexible steering, good stability, strong power, good mobility, small turning diameter, strong gradeability, high driving speed, low noise, low fuel consumption, smooth and comfort running. The humanized design of Dongfeng mini truck gives the driver to experience more driving pleasure; the cab uses full seal structure. It has the natural ventilation system, various striking meters and indicators, complete and convenient switches, graceful artistic color of the internal body, and the chair is designed according to the modern human body engineering theory, comfortable riding and open vision.

 Main Parameters
1. Fuel
It should adopt with different type of light diesel with the national standards under different temperature. When the ambient temperature is 4, it should use type 0 light diesels; When the ambient temperature is <4 ,it should use type -10 light diesel; When the ambient temperature is <-5, it should use type -20 light diesel;

2. Location of Nameplate, VIN and Engine Number

2.1 The data plate should be located at the middle of the internal cab of the right side column. 2.2 The vehicle identification number should hit in the middle front part of the frame right-side
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beam. 2.3 The engine number is on the engine data plate.

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

Items Overall dimension Length Width Height Length Width Height Units Basic Parameters 4700 1770 2100 2800 1650 400 2850 1400 1278 1295 1500
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Dimension

Internal body dimension

mm

Weight Parameter

Wheel base Front tread Rear tread Rear suspension Unload weight

kg

Other Parameters

Loading weight Factory standard max. total weight No. of passengers(including the driver) Tire specification Engine model/power/output volume

person

2320 3950 2 6.00-14 YD480B/29kw/1809ml

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

1. Various operations
1.1 Door

devices

and

mechanism

When the door opens from outside, insert the key to

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the locking hole under the outdoor handle of the cab, turn the key, the door will be unlocked, and then draw the door handle, the door opens. As show in picture: Insert the key in the locking hole and turn it reversely to deadlock the door. It also works without the key, only have to press down the locking button, pull up the door handle, then close the door, the door deadlocks. Locking buttons are set on all the door glasses; press this button, the door will deadlocks. At that time, both outside and inside door handles could not open the door. As show in picture:

When the door opens, pull up locking button, then draw the handle, the door opens. Warning Do not left the key in the car.

During travelling, take the key out of the ignition switch is forbidden.
1.2 Door Glass Lifter

The glass lifter handle is located inside of the door, the glasses will raise or lower when turns the handle. As show in picture: 1.3 Chair The chair divides into the seat back cushion and the seat cushion. The seat back cushion fixedly installs on the chair bottom plate, the seat back cushion may turn over forward, and rotation handle is in the flank of the chair. Behind the bottom plate, there are two rotating joints fixed on the rear beam of the frame chair. Two hooks in front, the handle buckle are installed on the front beam of the seat cushion in order to fix the seat cushion. The drivers side chair can be forward and backward moved.

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1.4 Safety Belt Safety belt wearing (As show in picture) Drawing the safety belt lock, pass the should strap through shoulder, the belt crosses the pelvis ,then press the lock into the lock stand until hears clicking sound, press down the red button on the lock stand, the safety belt then will be unlocked. As show in picture: Drawing the safety belt on the shoulder upward through the tongue, the shoulder slanting belt can be adjust freely, the urgent locking mechanism of the safety belt will suddenly stop or deadlocks during the impact. Safety belt checking (As show in picture) Regularly check the parts including braid, lock catch, lock, rolling-up, fixed point and guide ring, replace the damaged safety belt and the one cannot work appropriately. Warning
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The driver and the passenger have to wear safety belt when the vehicle is travelling. The safety belt provides front part collision protection. The driver and the passenger seat at the front-row have to wear the safety belt during travelling to avoid injury from crashing or the fatal accident occurrence. The passenger is not allowed to seat in the cargo area, otherwise, once the accident occurs; they might get a more serious injury than the one who has fasten the safety belt at the seat. The lower part of the safety belt should pass the pelvis, do not fasten in the waist, the shoulder strip should fasten on the shoulder, do not slip into the arm. The safety belt cannot be twisted when wearing it, tightened comfortably with request. If the safety belt is loose, the person will not be able to obtain the safe protection. Make sure the safety belt lock catch inserts in the corresponding lock. Do not fasten the safety belt on the clothes pocket with hard pieces or fragile, otherwise, when the accident occurs, you may get injured from the goods fastened under the safety belt. Regularly check the attrition and damage of the safety belt, it should be replaced if it is over wears
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or damaged. After serious crash, should replace the used safety belt even it has no obvious damage. All safety belts after collision should be replaced (only if the accident is extremely small), even do not looks obvious. If the unused safety belt does not satisfy the operation requirement or damaged, it also should get replaced.
The safety belt should not get polluted from oil, chemical substance, especially the accumulator

electrolyte, may use moderate soap and clear water to clean the safety belt. In order to prevent mobile relaxation when use the safety belt adjusting mechanism, the user is not allowed to change or to add mechanism to the safety belt device. 1.5 The control device on the steering column (1) Lighting Switch
The lighting switch has 4 positions (As show in picture) LOCK This is the normal parking position; the key can only take out in this position. The ignition deadlocks once the key is take out. ACC
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When the key turns to this position, the radio and cassette player and the attached facility power are connected, but the engine has no power. ON When the key turns to this position, all power in the vehicle are connected, the engine is at the start-up condition. START When the key turns to this position, the engine starts, release the key, it will return to ON position automatically. Warning

Do not take out the key when the vehicle is moving, do not leave the child in the vehicle alone, and remember to take the key. Without anybodys looking after, the child is possible to cause the vehicle move and causes injure. Do not give the start-up motor to operate more than 5s for one start-up. If the engine does not work and has not started, wait for 10s and starts again. If it does not work after several times, then check the fuel and the ignition system. Do not leave the key at the ON position if the engine is not turning, otherwise the storage battery
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will be discharged.

(2) Combined Switch The combined switch is located underneath the steering wheel (As show in picture), the left and right multi-function control handle controls the front signal light, headlight, headlight variable light, left and right steering light through different motion mode. The function of various marks on the combined switch and the multi-function control handle are as follows:

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Left Control Handle This control stick is under the left side of the steering column, the operation is as follows: (a) Revolving the handle at the end of the left control stick to turn on or turn off the light. There are 3 control positions on the handle: all lights are disconnected at OFF position; front position light, tail light, plate light and meter light are connected at All above lights and headlight are connected at position, the headlight is not connected. position.

When the headlight turns on, down press the control stick to transform into upper beam, up lift to the middle position then transforms to low beam. When the upper beam connects, the upper beam indicator on the meter will be connected. Up lift the control stick, the headlight will become the variable light (returns when releases) (b)Steering Signal Forward and backward moving control stick may connect to the left and right steering signal. Turn right the forward push control stick, and turn left the backward pull control stick. Right Control Handle
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The control stick is at the right hand side of the steering column, it has 4 gears. INT: The windshield wiper is the gap gear; the gear is extremely suitable for fog and light rain weather. LO: The windshield wiper operates in a stable low speed. HIGH: The windshield wiper operates in a stable high speed. OFF: The windshield wiper will stop operating if it does not work. Upward lifts the control stick, spray the cleaning liquid, it restored immediately when releases, the cleaning liquid spraying stops. Warning In the cold weather that the windshield is freezing, it should connect to the defroster device before use the windshield wiper. Do not use the cooler anti-freezing fluid as the windshield cleaning fluid, such may affect the vision seriously, and will possibly damage the coating of the vehicle. In order to prevent damaging the windshield wiper and the clean system part, please pay attention to the following matters: 1. Do not attempt to use the windshield wiper for dust removal on the dry windshield, otherwise it
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will scratch the windshield, and damage the windshield wiper piece. Use cleaning liquid to moist windshield before use the windshield wiper, when the cleaning liquid does not blowout, do not continue to run the windshield wiper, otherwise it will damage the wiper motor. 2. 3. 4. In winter, clean the ice and snow on the arm of the wiper before use the windshield wiper. Check the windshield wiper system carefully before travelling, especially in bad weather. When add the cleaning liquid, only add to 3/4 of the liquid storage tank volume in order to ensure there has enough expansion space at the low freezing temperature when cleaning. 5. Use the qualified cleaning liquid that conforms to the stipulation.

(3) Horn The horn button is located on the steering wheel. When the power is connected, press the horn button, the alarm rings. 1.6 Dashboard and Various Switches (1) Holder (2) right control handle

(3)Combined dashboard (4) emergency flashlight switch (5) left control handle (6)
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other switches (7) radio and cassette player

(8) central vent (9) heater switch (10) front cover

plate switch (11) ignition switch (12) lighter (13) ashtray (14) tool box (1) Combined dashboard, speedometer, odometer The speedometer expresses the speed of the vehicle by Km/h The odometer shows the total travel distance, the smallest unit is 1Km. Fuel Gauge The fuel gauge shows the oil mass in the oil tank, when the indicator at F, diesel is full in the oil tank. At position E, the oil tank has no diesel. Water Temperature Gauge Indicate engine coolant temperature. During travelling, the coolant temperature should maintain at the normal range, the indicator moves towards H (high temperature) from C. If it surpasses the scope of H, the engine is over heat, and then stops the vehicle immediately. Left and Right Steering Indicator

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When the ignition switch is connected to the steering switch at the connecting position, indicator flashes, the steering light is also lightens, means it also gives the steering signal. Left turns, the left indicator flashes; when right turns, right indicator flashes. Headlight Upper Beam Indicator The headlight uses upper beam, indicator lightens.

Warning Indicator Emergency flashlight: press the emergency flashlight switch when emergency case occurs, emergent stopping, send out the warning light to avoid crashing with the coming vehicles, indicator flashes.

Warning Do not use this switch unless the emergency case occurs. Oil Pressure Indicator When the ignition switch is connected,
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indicator lightens immediately, after the engine is

start-up, flameout the indicator immediately. Otherwise, it shows that the engine sump oil level is too low or the lubrication system has breakdown, then turn off the engine immediately to check the oil level or replenishment. If the fault still has not fixed, should carry on the comprehensive inspection to the lubrication system. Charging Indicator When the ignition switch is connected, indicator lightens immediately, flameout the indicator

immediately after the engine is start-up. Otherwise, there is fault occurs to the accumulator system. Check if the fan breaks or looses first, if it is normal, then check the electric circuit. Bake Fluid Level Light Under the normal condition, when the ignition switch at the START position, indicator

lightens, if the light is not flameout when the engine starts or the indicator unusually connects during traveling, these shows that the brake system has the fault, should check it immediately. If the indicator unusually connects during travelling, drive the vehicle off the road to check the brake
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system in the roadside. Warning It might need longer parking distance, bigger pedal force and longer pedal distance at that time After inspection, if it is under the safe condition, drive the vehicle to the nearby repair shop with low speed, otherwise should tow the vehicle to the repair shop. Safety Belt Indicator When the ignition switch is connected, indicator lightens immediately. When the safety belt inserts to the fixed stand, the light disappears, it shows the safety belt is fastened. Parking Brake Light When the ignition switch is connected, at the unreleased condition. (2) Other Switches Front and rear fog light switch Front Fog Light Revolve the handle at the end of the left control handle at position , press the front fog light the parking brake light lightens if the parking brake is

switch, the light is on. When the front fog light lightens, press again, the light will be off. Rear Fog Light
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Revolve the handle at the end of the left control handle at the headlight switch position, press the rear fog light switch will be off. Lighter and Ashtray When use the lighter, press the button, when automatically eject a standard after a few seconds, it can be used once it draws out. Pull out the ashtray box when using, thrusts the ashtray after put in the cigarette ash and the cigarette butt. Attention: The cigarette butt must extinguish when put in to the ashtray to avoid the fire, and cannot put other sundry to the ashtray. Front Cover Plate Switch Pull out the front cover plate switch handle under the right hand side of the dashboard to unlock the front cover plate, and then put the hand into the middle of the front cover plate to lift the hook, lift up the front cover plate, and supports with
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, the rear fog light is on, then press the OFF button, the rear fog light

the outrigger. When close the plate, take down the outrigger first, lay down the front cover plate slowly, and then push down the front part of the plate, the front cover plate will be locked. Tool box Lightly lifts up the handle, the tool box then opens, jog the tool box board to close it. Attention: The tool box cover has to be closed to avoid anyone get injured when traveling. Radio and Cassette Player Basic Operation: Under the off condition, the display monitor shows the clock, lightly press
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the power button on the plate to start the power, and under the starting condition lightly press the power button to turn off the power. Press volume+ and volume- to adjust the sound. Press up and down button to change tracks. This player also supports arbitrary track insert playing. Inserts the USB or SD/MMC willfully, the song will played automatically.

Heater System (1) Unidirectional ventilation ---- blows the face The wind is sending out through the dashboard central vent and the side vent. (2) Bidirectional wind The wind is sending out through the dashboard central vent and the bottom vent.
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(3) Unidirectional blast----blows the leg The wind is sending out through the floor air vent (4) Defrost and blows the leg The wind is sending out through the floor air vent, it has few winds sending out through the windshield defrost air vent and the side defrost air vent. (5) Defrost The wind blows from windshield defrosting vent and side defrosting vent. (6)Internal and external circulation control button The internal and external circulation of air is controlled by the button. (7)Temperature control buttons Control temperature of cold air (blue)/warm wind (red). (8)Air volume choice button It is used in air regulation. (9)Ventilation position choice button
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The warm wind can be selected to blow from the above vents by pressing the button. 1.7 Other control device (1) Brake parking lever When parking, brake rod is pulled and wheel brake is blocked. Then the parking brake is released and operator needs to press the button on top of brake bar and then replace the bar. Warning: When leaving the car after parking, parking brake must be used. At that time, transmission should be in reverse gear or gear 1. The car cannot be used when the parking brake is blocked, otherwise there will be permanent damage to the braking system. If the parking brake cannot be blocked reliably or unlocked, the car needs repairmen. (2) Pedal 1 clutch pedal 2 brake pedal 3 accelerator pedal
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Attention: Unless necessary, dont put your foot on the clutch so as not to wear. (3) Gear lever First gear: Bring to the left and then push forward. Second gear: bring to the left and then pull backward. Third gear: push forward when in the central position. Fourth gear: pull backward when in the central position. Fifth gear: bring to the right and then push forward. Sixth gear: bring to the right and then pull backward. (4) Fuel tank filler When refueling unlock fuel tank tap and fasten it tightly after use. Warning when refueling one should uncover the lid slightly for fear of fuel discharging. (5) Sunvisor
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Sunvisor is equipped to block the sunlight and ensure driving safety. (6) Interior mirror Interior mirror can be turned up and down along the central axis. (7) Exterior mirror Driver can see the vehicles and objectives through the mirror. (8) Safety handle Handles are installed at the side wall of seats (except drivers seat) Warning Passengers should strain the handles. Nothing can be hung on the handles so as not to block drivers view. (9) Vehicle-mounted tools One set of tools is available to repair at any time. (10) Engine cabin When opening the cabin:
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A. put the seat back to the seat cushion. B. unlocks the two hangers. C. lifts the seat slowly and then fixes it. D. use the opposite way to close. Warning When opening or closingone should be raise or lay down the seat slowly. After opening the cabin, make sure seats and back are adjusted to the right place and deadlock the seat. (11) Car body Ternary doors design is employed. Warning When driving the floor of car cannot be lay down to avoid influencing the indicator light and causing accidents.

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2 Vehicle use

2.1 waste gas warning Waste gas is filled with CO gas, harmful deadly gas, which is difficult to test. We must pay attention to following points to avoid waste gas: Engine is not allowed to operate in the garage or any closed region. Snow and leaves should be cleared out of the vent frequently. Regular inspection should be done for exhaust system. 2.2 Starting engine Before starting engine, we should ensure that braking is locked and gear lever is in the neutral position. Spin the ignition key to STposition and connect starting dynamo until the starter fires and operates. Warning Starting motor should be stopped and the key should be released after the engine is started.
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Starting motor should be stopped when the starting system is out of order. The time for starting motor should be less than 5 seconds. If it fails, restart it after 10 seconds. Dont idle the engine with high speed after it starts. When starting, push down the clutch pedal and make the transmission to first gear. Then let go the parking brake, push the pedal down and release the clutch slowly. 2.3 Transmission use All the forward gears adopt synchronizer ensuring smooth shift. Before shifting, the clutch should be separated completely. Before running on downhill or steep hill, the speed should be reduced and low gear should be used with engine braking. Long distance brake of braking system should be avoided so as not to make it overheating and invalid. When walking on the smooth roadwalk slowly before changing to low gear. Sudden change of engine speed may make the vehicle skid. Attention
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Dont push down the clutch pedal for a long time to avoid the damage. When shifting, one needs to push the pedal completely.

2.4 Brake The vehicles braking distance increases along with the driving speed. We should make sure that the vehicle has enough distance before parking. Warning There will be screaming when braking which needs inspection. Dont use continuous brake for long time or push down the pedal when walking. When water is flowing into brake drum, the brake will become invalid. Therefore, when the vehicle travels through water or after it has been washed, we should push down the pedal slightly at low speeds, operate the brake repeatedly and make the brake dry and recover. Clean the brake after walking on sandy road to avoid wear. Vacuum booster is employed to ensure smooth brake.
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2.5 Running in In run-in period, we should operate carefully to maximize its performance. We should comply with the following instructions within the first 1000 km range: 1. Dont run the engine with high speed after starting. It needs warming up. 2. Dont run at fixed speed. If frequently changing speed, the moving parts can get good run-in. 3. It is strictly prohibited to urgent acceleration. 4. Avoid sudden braking as far as possible. 5. Dont walk slowly at high gear. 6. Dont use trailer in the run-in period. 7. Try to avoid walking on mud or sand roads. 2.6 High-speed precautions a. The higher the driving speed is, the longer the braking distance is. As a result, the braking pedal is controlled depending on the driving speed and needed braking distance.

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b.

When passing the mountain pass or portal, the vehicle will be influenced by lateral tuyere; we need to reduce the speed to avoid unexpected vibrating.

2.7 Driving on slope You have to change down when you drive uphill to avoid the overload of engine. Pay attention to the following points: a. You have to change down when you drive uphill to increase engine torque. Shifting should be rapid and timely for fear of flameout of the engine. b.
c.

When running downhill we need to shift down using the engine to brake. Always dont make the engine speed too high.

2.8 Driving on slippery surfaces When walking on the wet or snowy roads, the adhesion of tyre and ground will be decreased losing control of steering and braking. Therefore driving at high speed is forbidden. Attention:
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a. Dont use wore tire. By Necessity, we must reduce the speed. b. Always keeps low speed avoiding sharp turn, nasty start and emergent braking. 2.9 Economic driving We can improve fuel economy as following: (1)Avoid too much idle speed If we need to wait for a long time, we can stop the engine using parking brake. (2)Avoid rapid start Rapid start will increase unnecessary fuel consumption. (3)Avoid unnecessary parking Avoid unnecessary parking. (4)Keep the cleanness of air cleaner If the air cleaner is too dirty, the air input will be reduced causing incomplete combustion and fuel waste. (5)Keep regular load
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Overload will cause much fuel consumption. (6)Keep normal tire pressure Low tire will increase running resistance waste fuel. 2.10 Load Don't let vehicles overload.

Maintenance

and Inspection

We need to maintain the vehicle in a planned way, strengthen inspection and adjustment and ensure that the vehicle is in good condition. The maintenance of vehicle consists of routine maintenance and periodic maintenance which is divided into Grade I, Grade II and Grade III.
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1. Regularly safety precautions of routine maintenance

Be careful doing inspection and maintenance. Pay attention to following points: 1) 2) Dont start engine in garage or other prohibited area. One needs to pull up hand brake and put the transmission into the neutral position if it is necessary to start the engine for maintenance. 3) When the engine is runninghands, cloths, tools and other objects should be kept away from the rotating fans and belts. 4) 5) 6) 7) 8) Dont touch high-temperature parts such as exhaust pipe of engine and silencer. No smoking around diesel oil or battery for fear of fire. When using lifting jack one cannot get to vehicle bottom. Pay attention to connect anode and line in a right manner to avoid short circuit. When cleaning and maintaining, prevent the water from getting into control module.

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2. Routine maintenance

Routine maintenance for the machine is the mandatory daily work, main contents: a. Insists on inspecting safety mechanism and connections of parts before, between and after driving. b. c. Keeps the cleanness of machine oil, air filter and battery. Avoids leakage of water, electricity, gas and oil.

Through inspection we can take targeted measures.

3. Periodic Maintenance

3.1 Regular maintenance projects and due time The following two tables set Kilometers traveled or months as maintenance time, Maintenance symbols:
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G---replace R---lubricate X---wind to certain torque J---inspection T---regulate

(1) Regular maintenance projects and due time Due time project Empty filter cement or the asphalt pavement Empty filter sand road Fuel tank. oil tube and
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km

10

20 12

30 18

40 24

50 30

60 36

70 42

80 48

months 6

clean every 10000km, replace every 40000km

clean every 2500km, replace every 4000km J.T ----J.T.G ------J.T.G

coupling Fuel filter Electrical wiring, coupling and light clutch Brake fluid(liquid level, leakage pollution) Brake pedal(stroke) Hand lever and dragline Brake drum and brake shoe (abrasive) Brake hose and pipeline (leakage damage)
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G ---

G J.T.G

J.T.G ---

J.T.G ---

J.T.G ---

J.T

J.T

J.T

J.T

J.T

J.T

J.T

J.T

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

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

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

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

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

tire(abnormal wear and air pressure) tire nut(damage. compactness) Bolts and nuts(compactness) Steering gear(gap. compactness)

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

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

---

---

---

---

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

(2) Maintenance for bad driving conditions If your vehicle is used in bad conditions, you can refer to the following table for maintenance. Bad conditions BC ACDE BC
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parts driving belt engine oil and oil filter driving belt

Maintenance J.T.G G J.T.G

interval 10000km or 6 months 5000km or 3 months 10000km or 6 months

ACDE ABD C BE

engine oil and oil filter Exhaust pipe and the device air cleaner cartridge Transmission and nut

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

5000km or 3 months 10000km or 6 months 2500km or 3 months 20000km or 12 months

B ABC

Chassis bolts and nuts brake drum and brake shoes

X J.T.G

10000km or 6 months 10000km or 6 months

A: repetitive short-range running B: run on the rough and muddy road C: run on the dusty road D: run on the extremely cold or salt road E: repetitive short-range running in very cold weather 3.2 Regular service content
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(1)Instrument and indicator lights Turn the ignition lock to connecting position. Test indicator light and fuel meter. After starting the engine, test indicator light and water temperature gauge. After driving, test the milometer. (2) Lights Check the lights are functional or not. (3) Speaker, Directional signal, wiper and scrubber Check speaker, Directional signal, wiper and scrubber function is normal or not. (4) Door lock Check the door lock function is normal or not. (5) Internal and external mirror Check whether we can get good rear vision on drivers seat and adjust. (6) License tag Check whether the tag is clean, fixed and legible. (7) Suspend
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Check whether the vehicle suspends and repair if it is necessary. (8) Fan belt If the fan belt is too loose, it will cause overheating of belt and premature wear. Use your thumb to press the belt, there will be 6-8mm sinking. Belt adjustment and replacement a. b. c. Stop the engine Loosen the bolts which connect the engine. When tightening beltpush the engine outward and tighten the bolt until the compactness fits the needs. d. When replacing beltloosen the boltpush the engine inward and replace the belt.

(10) Engine lubricating oil should select specified oil according to temperature. Oil surface check: The correct amount of lubrication oil is important for the lubrication of engine. Put the vehicle on a level surfacetake off oil level indicatorclean it and get into oil hole which should

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be between the scales. Again into the oil hole, should be between scales. If near the referral, we should apply after filling oil, start the engine and idle running for a while, and then check a ruler.

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

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Before dismantling refueling mouth screw, feel the temperature by hand and twist off when it is cool enough. Unused or used oil should be kept in safe place. (11) Gear oil When you add or replace transmission or differential gear oil please adopt the oil below: Item transmission Differential Oil position check Refer to the steps: a. Put the vehicle on a level surface and strain hand shake. b. Dismantle the refueling mouth screw. c. put your finger into oil outlet to feel the amount of oil. d. Mount refueling mouth screw. Warning
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Oil type APL.GL-4 APL.GL-5

Recommended oil SAF75W-90 SAF80W-90

After driving the temperature of gear oil will be high. Before dismantling refueling mouth screw, feel the temperature by hand and twist off when it is cool enough. Gear Oil Exchange When changing oil, follow the following steps: a. b. c. Tear apart the drain access plug Tear apart the purge cock to exhaust the oil and reinstall the purge cock. Choose the seasonable oil and fill it into the assigned position from the oil filler.

Attention: When wresting the plug, please using the GY-210 seal gum to prevent leaking. (13) Motor Liquid Coolant If the liquid coolant is not enough, it needs to filling-up. It is dangerous to open the heat radiator when the motor is hot; you should open it when the motor is cooling-down. (14)Glass Scrubbing Solution Dont use antifreeze in the windshield washing tank, which will influence the view and maybe damage the paint layer of the truck.
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When there is no water in the washing tank, do not work, otherwise, it will damage the electric motor. (15) Air Filter If the air filter is clogged by the dusts, it will increase the inhalation resistance, so the motor power will be decreased and the oil wear will be increased. You must clean and change the filter element. Cleaning method: lift down the lid of the air filter and take out the filter element and use the compressed air to blow away the dusts above the filter element. (16) Brake Fluid The fluid level should be between the highest and the lowest fluid level. You should add the same brake liquid when the fluid level is low. Warning If the liquid level of the brake fluid reservoir is too low, the light on the instrument desk will be lighted to prompt filling-up.

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Dont use different brands brake fluid, outdated and no-lid container brake liquid. (17) Brake Pedal When the brake pedal is treaded forcefully, the distance A (see as the picture) between pedal and anterior wall cannot less than 95mm. When the following situation happens, it shall be maintained: a. b. c. d. e. Lack of brake force Unsteady of brake Block of brake Have brake noise When treading the pedal, the pedal kicks.

(18) Clutch Pedal The free stroke of the clutch pedal is 15-25mm; too long or too short is not suitable. (19) Tire In order to avoid the unbalanced wear and tear to prolong the operation life, the tire should be exchanged as per 10000 km. When exchanging, you should readjust the pressure of front and rear
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tires. When the tire is inflated, you should inflate it and meanwhile check the pressure to the assigned position. When using the tire, you should do the following checking: a. b. c. d. To check the wear and tear situation of the tire tread so as to ensure whether it needs change. Whether there is inordinate wear or not, fish mouthing and impairment of tire. Whether there is any iron nail or not, stone or other stuff penetrating into the tire or tread. Whether there is rapping of wheel nut or not.

(20) Accumulator If the battery electrolyte always needs to keep between the high order and low order, it should replenish electrolyte till to the high order line. When the post head appears white powder, it should be washed out by mild water, then daubing up the consistent lubricant. However, please pay attention to that dont wet the accumulator. Every month, the accumulator should be in charged so as to prolong the operating time. Warning
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When inspecting and maintaining, you should switch off the ground lead to avoid short circuiting. (21) Screen Wiper If the wiper blade is with brittle fracture or broken, it should be changed immediately and in order to avoid brush burn to the glass, please dont brunt glasses when you demount the blade. (22) Parking Brake When parking brake is dead locked, the number of teeth which ratchet wheel can tell should be more than 7. If within this range, the brake cannot be completely deadlocked or unlocked, you should check it. (23) Steering Wheel To turn the steering wheel from left to right slowly until you can feel a little bit resistance force, then measure the rotating distance which should be within the assigned value. On the flat and wide land, you turn the steering wheel from left to right until it cannot move to see if it is easy and convenient to steer. The play of steering wheel is 0-30mm. If it exceeds the play range, the wheel should be inspected and adjusted.
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Malfunction Analysis and Elimination

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

2. Malfunction of Clutch System

Problem

Cause Free stroke of pedal is too short The friction wafer is fraying and with greasy dirt

Solution Adjust Change or Clean

Clutch Track slip

Clutch pressure disk or flywheel face is distorted The pressure of diaphragm spring is not enough

Change or repair

Change

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Free stroke of pedal is too long Diaphragm spring is weaken Declutch of clutch is not thorough Pitting of the input shaft spline Damage or abrasion of the input shaft spline Rapture of pull-off spring Abrasion of friction wafer Rapture or damage of pull-off spring Clutch Shudder Lacking oil or damage of release bearing Differential pressure of diaphragm spring Rivet rapping of friction wafer

Adjust Change Lubricate Change

Change Change Change Change or lubricate Change or adjust Repair or change

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3. Malfunction of Gearbox System

Problem

Cause Abrasion of gearshift shaft Abrasion of synchroshifter gear sleeve

Solution Change Change Change Change Adjust Adjust Change

Out of gear Weakness or damage of guide spring Bearing abrasion of input shaft or basic shaft Declutch of clutch is not thorough Unsuitable adjustment by operating gear Difficult to shift the gear Abrasion of chamfering on gear sleeve or gear Deformation of gearshift shaft Lack of grease oil or unsuitable kind Noise Damage or abrasion of bearing Change
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Change Replenish or change

Damage or abrasion of gear Damage or abrasion of synchronizer gear ring Abrasion of chamfering on gear sleeve or gear 4. Malfunction of Compensating Gear System

Change Change

Change

Problem

Cause The gear compound is deteriorate or wetted

Solution Change oil and filling-up

Gear noise

The clearance between drive gear wheel and follower gear is not matched Drive gear wheel and driven gear is not match

Adjust

Adjust or change

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Rapping of fixed bolt on driven gear Damage of half axle gear or drive gear wheel on compensating gear The gear oil is deteriorated or wetted Bearing noise Drive gear wheel bearing is damaged Half shaft bearing or rear axle bearing is damaged Breather plug is blocked Oil leakage Oil seal is abrasive or damaged Too much oil

Adjust Change

Change oil and filling-up Change Change Clean Change Adjust

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

Problem

Cause

Solution
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The tire is abrasive The tire pressure is not suitable Off tracking of wheel The front wheel is out of position The front and rear plate-form spring is misplaced or ruptured The front wheel is out of position Inordinate wear or excessive wear of tire The truck is overloaded Bush bearing is abrasive or rapping The wheel or tire is waggling The tire pressure is not enough Wheel hop Shimmy of front wheel The tire is with bulge or damaged
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Change Adjust Adjust Adjust or change

Adjust Check Check Check Adjust Change Change Change

The tire is with bulge or damaged The turning track rod is abrasive

The drag link is rapping or abrasive The tire pressure is not enough

Adjust or change Gasing to the prescribed value

Difficult turning

The front wheel is out of position The front axle is overloaded Steering post is clamping stagnation The plate-form spring is misplaced or

Adjust Alleviate loading Check and adjust Adjust or change

The truck is low or not ruptured accordant Overloaded Too much emergency braking, the speed is too fast on unsteady road Plate form spring is cracked on bad roads U-bolt is rapping Adjust
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Alleviate loading Avoid emergency braking, reduce the running speed

The dash pot is out of efficiency The rubber articles of the suspension system is ageing or damaged It is noisy when driving Not maintenance on time

Change Change

Keep maintenance on time

6. Malfunction of Braking System

Problem Weak braking force

Cause Brake pipe leaks oil There is greasy dirt or water between brake drum and shoe plate The arrester is overheat The brake shoe is abrasive

Solution Check and change Clean or change

Repair or change change

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The wheel braking cylinder is abrasive change There is air in the system Non-uniform of braking There is greasy dirt or water between brake drum and shoe plate The brake clearance is not matched The tire pressure is uneven The fluid flowing of brake pipe is not smoothy The suspension element is rapping The pedal travel is too long Local fault of braking system Lacking of braking fluid of liquid storage pot There is air in the braking system exhaust
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exhaust Clean or change

Adjust or change Gasing check and change

check and adjust check and adjust filling-up brake fluid

The plunger of master pump cannot return correctly Malfunction of brake returning The return spring in the arrester gear cannot return The wheel piston cylinder is jammed Lacking of braking fluid The braking warn light is Brake pipe leaks oil lighted after motor starts up Malfunction of warning light circuitry When parking braking, the braking light is not lighted 7. Malfunction of Power Supply System Malfunction of circuitry

check and change

check and change

check and adjust filling-up check and change check and adjust check and adjust

Problem
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Cause

Solution

The Backup fuse is burn out The light is burnout When the motor stops, the The wire joining is loose charging light is not lighted The electric brush or the slip-ring is with poor contact The driving belt is loose The motor is working but the Malfunction of electric generator charging light is not blanking Malfunction of circuitry 8. All sorts of light fitting malfunction

Check and change Change Check and adjust Check and repair

Check and adjust Check and Repair Check the circuitry

Fault Front lamp off

Reason Lamp bulb damaged Switch fault

Solution Replace Check and repair

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Fuse blown Lead wire or earthing fault Lamp bulb damaged Fuse blown Front and rear fog lamp off Switch fault Lead wire or earthing fault Lamp bulb damaged Backup light off or cant be turned off Fuse blown Backup switch fault Lead wire or earthing fault Lamp bulb damaged Braking lamp off Fuse blown Backup switch fault
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Replace Repair Replace Check and repair Check and repair Repair Replace Check and replace Check and replace Repair Replace Check and replace Check and replace

Lead wire or earthing fault Directional signal, alarm relay fault Steering lamp off Combination switch or alarm switch fault Fuse blown Measurement unit fault Fuel indicator, water Fuel indicator fault temperature gauge dont work Lead wire or earthing fault sensor Lamp bulb damaged When the brake fluid is too low, the alarm is not on. Fuse blown Line fault Brake level switch fault

Repair Check and repair Check and repair

Check and replace Check and replace Check and replace Repair Check and replace Check and replace Check and replace Check Check
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9. Accessories malfunction

Fault

Reason Fuse blown

Solutions Check and replace Check Check Repair Clean or replace Check Check Repair Check Check Repair

Wiper malfunction or non homing

Electric motor fault Switch fault Lead wire or earthing fault Rinse the hose or nozzle blocking Electric motor

Scrubber malfunction Switch fault Lead wire or earthing fault Fire switch fault Cigarette Lighter malfunction Cigarette Lighter fault Lead wire or earthing fault
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 Emergency Treatments

1. Tire replacement

1) 2)

Take out the jack from the vehicle amounted tools Stop the vehicle on the flat solid ground, if the vehicle stopped on the road, turn on the emergency flash

3)

Lock the parking brake, make shift level into reverse gear, and fix it with hard objects under the wheel.

4)

Loosen the wheel nut by the wheel wrench, but do not remove it.
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5) 6) 7)

Put the jack under the jacked part; jack the vehicle slowly and smoothly. Remove the nut and tire, install the new tire and fix the nut by hand. Lower the jack, tighten up the nut in the cross order by the wrench.

2. Bridge connection starting

When the vehicle is unable to start, please use the following method (1) Use 12V battery lap start the vehicle, place another good battery in the vicinity of your vehicle in order to take the enough wiring length. Lock the hand brake of the vehicle. (2) Connect one end of the wire to the anode of the battery; connect the other end to the anode of the rescue battery. (3) Connect your second wire to the cathode of the rescue battery; connect the other end to the unpainted connection metal parts of the engine from the power shortage vehicle. Warning
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Do not directly take the bonding jumper wire connected to the power shortage battery cathode, as it may produce an explosion.

3. Engine overheat

The starter fault: (1) Turn the ignition switch to START location, turn on the headlamp, if the lights is very dark or gradually go out, it indicates that battery has power shortage or poor contact between electrode wires. (2) If the headlamp runs properly, check whether the fuse is fused. Engine overheats: (1) In the process of moving, if the water temperature table displays the temperature is too high, do as the following:
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a. b.

Park the vehicle in a safe place. Make the engine do the idle running for several minutes till the water temperature between H and C.

(2) If the water temperature gauge indicates no drops: a. b. Turn off the engine; inspect the water pump belt for damage or slipping. Inspect the radiator to check whether the radiator, water pump and water pipe have water leakage or not. If do, dont start the engine. c. Warning If you hear or see a steam leak, drive the car to a safe place, stop the engine and make it cool. Do not open the engine compartment. When you are not able to see or hear the steam out, open the radiator cap to check whether it is boiling, open it after it cooled. If no water leakage, fill right amount of cooling fluid.

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 Body Maintenance
1. Measures of protection

In order to prevent your vehicle from corrosion, here are several kinds of corrosion causes of automobile for your reference: (1) Salt, dirt, moisture and chemical substance accumulated in the vehicle floor or the part of the car frame which is difficult to touch for a long time. (2) Paint peeling, injuries or other damage are the causes of corrosion. (3) High temperatures will accelerate corrosion speed. (4) Some part of the truck will accelerate corrosion speedily if stay in the wet environment for a long time. How to avoid the corrosion? Keep the truck clean & dry. Clean the dirt in truck, dont park truck in damp, poorly ventilated place.
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2.

Vehicle interior cleaning

At the time of cleaning the car, do not use the spray diluents or other flammable materials; do not use bleach or strong-alkaline household cleaners. Vinyl resins of decoration Light wipe the decoration with a sponge or soft cloth using wet-water and a small amount of soap or gentle cleanser, after a few minutes, light wipe it clean by a clean soft cloth with water. Fiber material cleaning Clean the dust with vacuum cleaner, wipe the dirty place with a clean dip mild soapy cloth, and wash it with clean water after cleaning.

3.

Body cleaning

Dont clean or wax the car when the engine is running.

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3.1 Rinse away the sand and gravel on floorboard or wheel with high pressure water gun. 3.2 When washed the car exterior, wipe with soft cloth, dont use hard objects do the cleaning to avoid abrasion on the vehicle surface. 3.3 Take some cleanser with the soft cloth, wipe lightly on the car surface when washing the car. 3.4 Wash with water once it cleaned. 3.5 After cleaning, wipe the water beads with a soft cloth, making them natural dry.

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 Fuel and Lubricating Oil, Vehicle Mounted Tools

1. Fuel/lubricating oil/coolant/scrubbing solution

Item Fuel

Using part Fuel tank Engine

Specifications 0# light diesel oil SE grade 10W/30(for winter) SE grade 20W/50(for summer)

Lubricating oil Transmission Rear axle differential Coolant Scrubbing solution Braking fluid
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Gear oil 75W/90 GL-4 Gear oil 80W/90 GL-5 Antifreeze solution 82E-40(CA-01) ZT-30 GB10830JC3 grade

radiator Scrubbing solution tank Braking system

2.

Vehicle mounted tools list

No. 1 2 3 4 5 6 7 8 9 10

Spare parts No. 39C-01031 39C-01033 39N-01033 39C-15010 39C-01100 39C-01120 39C-01140 39C-01146 39D-01058 QYL5

Spare parts Double opened wrenchS8S10 Double opened wrenchS13S16 Double opened wrenchS16S18 Small wrench Phillips screwdriver assembly One glyph screwdriver assembly Carp clamp assembly Tire pry bar and Jack rocker Wheel socket nut wrench 5T oil pressure jack

Quantity 1 1 1 1 1 1 1 1 1 1

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