© DONGFENG EQ1141G HQ1146G EQ1168G SERIES TRUCK OPERATION MANUAL DONGFENG MOTOR CORP., LTD.© Foteword ies Welcome you purchase and use DONGFENG series forward control cab truck. And we hope our truck will bring your unlimited wealth with our heart How to obtain optimum performance from your new DONGFENG truck is the common target for you and us, but it will depend largely upon the extent of your familiar with the truck and your whole careful maintenance. We cordially _ _ hope you read this manual thoroughly and know heartedly the operation procedures contained. More attention please. The diagrams and description in this manual are correct when it is edited. At same time DONGFENG Motor Corp., ltd reserves the right to change the procedures, material, specification, dimensions or design of the truck shown, described or referred to herein at any time without prior notice in accordance with the Company’s policy of constant product improvement and innovation. In addition, this manual used for whole series truck models and there is different model truck with different structure and option, so it may occur the phenomenon that the description in this manual ,which is not conformed with _ the structure of your truck. : This manual includes the truck models as following: EQ1141G7D, EQ1141G7D2, EQ1146G, EQ1146G2, EQ1141G EQ1146K, EQ1146K2, EQ1146G series EQ1168G7D, EQ1168G7D1, EQ1168G7D2, EQ1168G EQ1168K7D, E.Q3168G7D, EQ3146G,EQ3141G7D EQ4141G7D, EQ4146G, EQ4146V, FQ4146W The manual should be kept with your truck as a part of truck equipment. As for product “Quality guarantee” and “Spare parts” purchase, please « contact with Technical Service and Guarantee Department of DONGFENG Market and Sale Head Department. DONGFENG MOTOR CORP., LTD© How to use this manual ies) © Vehicle Iden Location: SOLEMN DECLARETION: acaba We will not bear the responsibility of the reliability, safety and Location suitability of the vehicle products, if appeared activities Important } mentioned as follows: Operatic Le Make bold to change the vehicle design or reassembly without Standar permission. Daily Cl Running 2. The original parts, changeable parts proved and fitting are Correct Equipment substituted by other parts. Fascia ¢ Key... 35 The load during operation is more than rated loadage and total Dee i Seat ... weight specified in this manual. Safety The meaning of symbol in the manual: Instrun Indicat Switch Contre AN NOTE: If you don’t observe the proceeding, body Ventil injury or part and assembly damage will be occurred. Air Cc ‘Warning: If you don’t observe the proceeding, severe Leyes AN body injury or fatal part and assembly damage will be ie a occurred. ‘Adjus Rear! Fire € Trianj Copyright: Tilt All rights reserved. NO part of this manual may be reproduced, stored in a Tetrieval system or transmitted in any form without prior permission of Cont COMMERCIAL VEHICLE CORPERATION OF DONGFENG MOTOR Conn Dum CORP., LTD. Starting — DONGFENG MOTOR CORP., LTD> © Table of Contents Vehicle Identify Location of Model Serial Nui Location of VIN Serial Number . Location of Engine Serial Number and Nameplate . Important Items .... 2 Operation and Adjustment of the Engine Meeting Standard ... 2 Daily Check 3 Running-in of New Correct Operation .... Equipment and Operation Fascia and Lever 6 Key . 8 Door 8 Seat . 9 Safety Belt . 0 Instruments Indicator and Warning Light 15 Switches ... 20 Control Switches . 24 Ventilators 28 Air Conditioning System Levers Accessories Refilling Fuel. 36 Adjustment Steering Wheel 36 Rear Fence Rail 37 Fire extinguisher. 37 Triangle Warning Plate 37 Tilting the Cab 38 Connecting Device and Operation of Semi-trailer. Connecting Device and Operation of Trailer.. DONGFENG MOTOR CORP., LTDTable of Contents Braking Operation. Parking ... Driving on Slope ae Maintenance and Adjustmen Check and Refill Coolant ............ Drain Coolant from Radiator Air Filter .... Engine Oil .. Engine Oil Filter. Fuel Filter, Fuel Filter with Water Separator, Fuel Pre-filter Bleeding the Fuel System .. By-pass Type Turbocharger .... Adjustment of Advance Angle Check Injector .... Adjust Valves Clearance. Check Cluich Fluid Level 2.000.000.0202... oe Adjust Clutch 63 Bleed Air from Clutch Line 64 Check Main Reducer Oil Level Check and Replace Transmission case Oil Maintenance of the Hub Bearings .... Adjustment of the Service Brake Check Brake Pedal’s Travel De ONGFENG MOTOR CORP., LTD —— Method of Rele Drain Water fr Toe-in Adjustr Check and Rey Check Steerin Check and Mi Fuse ... Replace the E Light Adjusti Subsidiary P! ‘Tyre Inflatin Replace tyre Check Tyre Dismount th Interchange Check Dum Table Mai Check and Periodic Pz Mileage Sc Data of M Engine ... Chassis .. ‘Tightenin Capacity Bulb... Oil and L Specific: ——y 0 Table of Contents eas ‘Method of Releasing Spring Brake Drain Water from the Air Tank .... Toe-in Adjustment Check and Replace Power Steering Oil Level .. Check Steering Wheel Free-play Check and Maintain the Battery Fuse ..... Replace the Bulb . Light Adjusting Method Subsidiary Power Starting .. ‘Tyre Inflating Device ... Replace tyre .......-.. Check Tyre Pressure and its Surface Dismount the Spare Wheel Interchange the Wheels . Check Dumper Lifting Mechanical Oil Table Maintenance Schedul Check and Maintenance Intervals Periodic Parts Replacement ..... Mileage Schedule of Filling Grease . Data of Maintenance and Adjustment Engine .... Chassis ...... Tightening Torque . Capacity Data .... Oil and Lubricating Grease Specification . DONGFENG MOTOR CORP., LTD@) Table of Contents teas © Pe Mass Data (kg) Dimension Data (mm) Performance Data ... Assemblies Structure ........ Vehicle } Location Locati Wheel and Tyre numb: Suspension VIN si Chassis Frame counte Steering System ... right ¢ Braking System Electrical System .... Cab. 3 Cab heater and Air Conditioner . Cargo body ... Lifting mechanism Power Take-off . oe Saddle. Numt Tools .. Diagram of Brake Line ... Diagram of Electrical Wiring ........ DONGFENG MOTOR CORP., LTD ee[Se# © Vehicle Identify es Vehicle Identify Location of Model Serial Number Location of VIN Serial number VIN serial number usually countermarks on the tail of right side rail Nz25.187 Location of Engine Serial Number and nameplate “renee. 1680@ Important Items « } 3.AC 12 Anas | access | engine 1. Exhaust brake switch 3. Hom switch | turned 2. Windshield wiper and washer switch 4. Key switch 4,.ON 5, Lighting combination switch mien positic §. ST. start tl when turn th been s Exhaust Brake Switch Te Turn the lever to “ON” position, the | exhaust brake indicator will come on. : | A The exhaust brake is then operative a = when the foot is removed from both the | accelerator pedal and the clutch pedal. = The exhaust brake will be released i when either the accelerator pedal or the woow clutch pedal is depressed. 2. The exhaust brake stops operation when | the lever is pushed to the “OFF” | faee ota ob | position. | _—© Instrument and Operation Key Switch 1.Key: The engine key can be inserted and remoyed at the “KEY” position only. 2. OFF: The truck power is cut off when the key is in “OFF” position. The engine stops when the key is turned from “ON” to “OFF” position. 3. ACC: Set the key at this position using any of the accessories (such as radio, wiper, washer etc) while the engine is not operating. The engine stops when the key is turned from “ON” to the “ACC” position. 4. ON: The engine will start and operate when the key turns to the “ON” position. Don’t turn the key to any other position while the engine is in operation. 5. START: Turn the key to the “START” position and start the engine. The key will returns to the “ON” position when released from the “START” position. And never turn the key to “START” position after the engine has been started. Note: A Never turn the key to “START” position after the engine has been started, or the engine will be damaged. The engine can be restarted only when it stops running. 25@ Instrument and Operation ies @ Light Combination Switch Win This switch is used for the light switch, dimmer Ls switch, passing switch and turning signal switch. 2. 3: Light Switch 4. When the knob at the end of the lever is turned 5. forward, the following lights will illuminate. 0 position: off. 1 position: front light, tail light, license light and instrument light, 2 position: headlight, front light, tail light, license light and instrument light. Turning signal light switch Push the lever forward, the light on the left is on. Pull Enj the lever backward, the light on the right is on. as Use (Black arrow in the illustrator) cS Z te low app Dimmer switch and passing switch The dimmer is used to change the headlights from high beam to low beam. The headlight “HIGH” beam will go on as long as the lever is pulled toward the driver from the “low” beam position. Use this switch to indicate your intention to pass a car driving in front Ho of you. Light is ON and OFF when the lever raise Us: and down to aware the front truck. In normal driving, if turn the passing light switch on, the passing light keeps on, no matter other lights condition. (Black arrow in the illustrator) 26im. Instrument and Operation MEEAN Windshield wiper and washer switch 1 Wiper stops s a 2. Wiper operates intermittently i ee 3 Wiper operates continuously at lower speed ‘>= a 4. Wiper operates continuously at high speed Mag 5: When the lever is pulled upward, washing fluid will spray out continuously. Note: 1.Use of the wiper along will scratch the A windshield, be sure to operate it with the washer. 2. Do not use the washer in this way, it will burn the motor. pee Engine idle speed adjusting knob Use this knob to adjust engine idle speed when the engine idle speed is over high or low. The engine idle speed be adjusted to approximately 650-850 r/min. Horn switch BS \ Use electric horn or air horn as required. Ly 27: Pa Instrument and Operation | | 2 Ventilators | Air! Door Ventilator Arr: There are triangle ventilation windows on the left and right doors. When a ventilator needs to open, press the knob as shown in the figure and turn the handle to release the glass of the window, turn the glass to require position. When require to close, turn the glass to lock position, and turn the handle backward, then the knob will spring back. Door Glass Turn the handle clockwise to raise the door glass. Otherwise the glass is closed. Rear Side Window Open this window for quick or constant ventilation of the compartment. 28 ‘aha© Instrument and Operation eas Air Conditioning system Arrangement of Vent holes H-B-050 Adjust Vent Hole Shield Adjusting the vent hole knob may change the air flow. 1. Adjusting vent hole knob 29) Instrument and Operation iS oo Control Panel Tra Whe clut: ) l© forv sure Whe ae : + posi bacl ae ; } I. Fan switch 2. Air lever 3. Temperature lever 4. Model lever 5. Air conditioner switch | | | FRESH—External air is introduced REC—Intcenal air is recirculated Parl The FACE—Head level as pi FOOT—Foot lever Modejever DEF—Front window and door back window park ‘As shown on the right figuee it can the] be realized head cooling and foot warming, If using in this way for | long time the air lever should be at | “REC” position. — 30© Instrument and Operation ipsa Levers Transmission Shift Lever When shifting gears, be sure to fully depress the Rrae clutch pedal. Before shifting the gears from the forward to reverse or from reverse to forward, be tea sure to bring the truck to complete stop. Lee: When the gear shift lever is set in the “R” (reverse) position, the backup light will cone on, and the backup buzzer will sound simultaneously. Parking Brake Lever = The forward and rear axle spring brake is acted as parking brake. When parking, pull the lever backward to locking position. To release parking brake, first pull up the lock sleeve of the lever, then pull the lever forward. 1. Releasing for forward 2. Braking for backward 3. Pull up for upward 31: ce © Instrument and Operation aay! Accessories Ash Tray Pull out the ash tray backward to use it. Detach the tray for cleaning by pressing down. Dome Light 1. position: This light will be turned on as long as one door opens and turned off when two doors are closed at the same time. 2: position: The light keeps off wherever the door is. By position: The light keeps on wherever the door is. Glove Box Keep the manual, road map, gloves and other small articles in this box. Use a key to lock the glove box. 32 l© Th suy cay Itz is) col or Th the© Instrument and Operation ea Working light socket The working light socket provides the power supply for the checking truck lighting. The capacity of this working light socket is 24V, 5A. It also can be used as the external power supply. AN Note: Make sure that the power usage is within the capacity of the socket connecting a checking truck lighting or used as an external power supply. Quartz Clock The quartz clock display time. You can adjust the time by pressing its two buttons. Inside Rear View Mirror You can adjust the angle of inside rear view mirror as you like. 9057 33i Ze Instrument and Operation Gussan Rear View Mirror and Lower View Mirror ‘The both left and right side of cab are equipped with view mirrors, but the lower view mirror is only mounted at the right side of cab. Both rear view mirror and lower view mirror are adjustable ‘ as the driver’s required. 1. Lower view mirror 2. Rear view mirror Cigarette lighter When lighting a cigarette, insert this lighter directly and wait for 10 seconds. As the front part of the lighter become red, it ejects automatically. At this time, you can take it out and light the cigarette. Put it back after lighting. Note: Never let the lighter switch on for long time. You must take it out, if the lighter switches on for long time and could not eject automatically. Fuse Box When you replace the fuse, pay more attention to confirm the fuse capacity and find out the relative fuse by the remark on the fuse. (Teese elec aD DDD SO DDS IDI > Os a mowers | 1 Starting engine 2.Preheat intake air 3. Shut-off solenoid 4. Backup light 5.Cab heater 6.Cabheater 7. 8. 9. Hazard warning signal 10. Parking light 11. Dome light 12. Turning signal 13. Cigarette lighter 14. Horn 15. Front fog light 16. Headlight (R. H-high-beam) 17. Headlight (R. H-low beam) 18. Headlight (L. H-high-beam) 19. Headlight (L. H-low beam) 34 Tay0) ni Instrument and Operation ey Radio Cassette Player (optional) Radio operation i? Turn the volume control knob clockwise, then the power is ON and get the proper volume to continue turning. 123710 89645 2. Use AM/FM wave switch to select the station you want. nome iB: Turning: turn the right front knob to select the station you want. 4. Push the wave switch to the FM stereo mode 1.Tone control knob when receive the FM stereo broadcast. 2.Power and volume Sometime, there is the noise, please turning ‘control switcit, i carefully. 3.Fast forward/eject button 4.Tune knob 5.Balance control Tape operating knob te Use the volume control knob to turn the power 6.AM/FM stereo ON, then put the tape into the tape box. The wave changer. contact face, which is between the tape and the _7-Stereo indicator magnetic recording head, is in the right side. 8.Needle 2. Adjust the volume, tone and balance knobs to "Frequency plate = : 10.Tape cover choose the optimum volume and tone quality. 3° The tape is fast forward when press the fast forward/eject button slightly and lock it. The tape will play continuously when press slightly again. 4, The tape stops and ejects when press the EJECT knob fully. Note: A 1.Don’t put the tape before power on. 2.Cleaning the magnetic head when the sound become obviously lower. 35© Instrument and Operation Anesaany ) | Refilling Fuel | tr Open the fuel tank cover, fill the Tria clear and specified grade fuel. far | easi 1. Fuel tank cover Adjustment Steering Wheel Loosen the lock lever, the steering wheel can be tilted forward and backward and the axle telescoping R can be extended or shortened. Before adjust the i steering wheel, adjust the seat to suit the driver’s < body. After selecting the desired position, be sure to 0 tighten the lock lever securely to prevent the steering wi wheel from being accidentally moved while the truck is in position. fen real Note: fix J Never attempt to change the flat steering Wheel position while 1, Lock lever ave driving. Bi Tl be © (SS SET SEE 36© Instrument and Operation ies Triangle Warning Plate Triangle warning plate must be placed 50m far from truck and other drivers can be see it easily. wezoesm 1. Triangle waning plate Rear Fence Rail The rear end of chassis frame should be equipped with rear fence rail, light reflectors are mounted on the fence rail and fence rail bracket. When a truck equipped with an overturn rear fence rail is driving on a high passing road, the rear fence rail can be adjusted by turning up and ree fix it with a pin. When the truck is driving on a flat road, the rear fence rail must be put down to avoid such a car and so on going in. Fire extinguisher The fire extinguisher is fixed on the cargo body. The operation procedures of the fire extinguisher is described on the extinguisher. EEUU EEE EERE 37© Instrument and Operation | | Tilting the Cab | Ope Precautions for tilting the cab: | 1. Br I Try to position the truck on ad flat a | have surface as possible es 2k When tilting the cab indoors, ensure | 2. Re that there is sufficient clearance | fever between the truck and the front wall, 3.Pt and between the truck and the ceiling. 1. Lock pin 2.tilting lock lever the s 3! Operate the parking brake lever 3. safety lever 4. A securely and put the gearshift lever in push NEUTRAL. Place a tire chock under Sip each tire as necessary. lever 4. Remove loose articles, such as road maps, magazines etc. From the seat and bed of the cab. Operation of Tilting the Cab E Remove the lock pin (1) out of tilt lock lever (2) Be Pull the safety lever (3), and fully pull down the tilt lock lever (2) until fit its holder(4). So the cab will tilt fully. If the cab can’t be tilted, assist by lifting manually 3: When the cab is tilted, check that the folding support lever (5) is fully i extended and fit its safety pin (6). oe en 38© Instrument and Operation Operation of Locking the Cab 1. Ensure that no gloves, tools, dash cloth etc. have been left on or around the engine, especially around the exhaust pipe. 2. Remove the safety pin from the folding support lever and fit it into the upper hole. 3. Push the tilt lock lever up, lowering the cab, at the same time buttress the handle of cab. 4, After the cab will be put down completely, push up the tilting lock lever. 5. Insert the lock pin into the hole on the tilting lever s Note: AN 1. When pull tilting stopper up, please don’t stand under the cab for the cab will fall down as its weight. 2. It is important to insert the tilting lever into the hole on the tilting lever to avoid the cab tilted during driving. 39@ Instrument and Operation eas) © Connecting of Semi-trailer Connecting device There are coupling device in the rear of the towing vehicle. The bridge hose joint This joint is used to connect the hose for transferring the brake compressed air and the brake control air pressure from the tractor to the trailer. The air supply joint is at the fight of the longitudinal symmetrical plane (look from rear) and the control signal joint is at left. The bridge cable joint This joint is used to connect the cable for transferring the electrical signal to the trailer. Saddle Model 50# saddle is used, easy to connect or remove, reliable to connect. Rear! This li the tra H.nos208 1.Bridge cable joint 2.Control pipe ‘cA 3.Supply air line© Instrument and Operation theca Rear light of the cab This light is used to connect or disconnect the trailer at night. Connecting Operation 1. Adjust the height of tractive king pin connecting surface by a supporter to lower than the base level of tractor connecting device 50-80mm. A Note: The connecting operation must be done on flat ground and parking brake must be effective clog the wheel. 2. Confirm the clip claw of connecting device to be opened normally. 1, Rear light wees 205 1.Saddle 2.$-form hook 3.Supporting foot Ch 4@ Instrument and Operation ea © 3.Slowly move the tractor backward to 1 2 3°04 connect the towing hook and ring. 8.Turn disconr > | 9.Start Hnns-20- air rese 1. Towing truck 2. Connecting device 10.Rele 3. King pin of trailer 4, Trailer stop br: 11.Stoy 4.Insert the locking pin backward, turn lever 0 the handle 180° in opposite . normal direction, then latch the pintle. 12.Ens — 5.Hang the trailer’s safety train to the safety pin. They are both at : acl outside of the longitudinal beams. Discon | 1.The1 chock 2.Clos: 6.Insert the trailer’s cable joint into the pressui tractor’s socket. 3.Disn power ieee the tra & 4.Rem longitt 7.Connect the bridge hose joint with vacl 5.Rais the tractor’s air pressure output hook. joint. Ensure that is connected correctly. — 42© Instrument and Operation 8.Turn on the disconnected switch (there are two ——- disconnected switches). 9.Start the engine to rise the air pressure in the air reservoir at the specified pressure. Lae 10.Release the parking brake and the trailer’s stop brake. 11.Stop on brake pedal, ensure that the push Jever of the trailer brake chamber is working normally. 2 1. Close 2. Open 12.Ensure that the trailer ling is normal. 1.05.20 Disconnected Operation 1.The trailer brake is acted on. And place a chock under the trailer’s tire. 2.Close the disconnected switch of the air == j= = pressure output. oj = 3.Dismount the air pressure output hose and Z power supply cable, open the towing hook then the trailer is braked automatically. 4.Remove the safety train at both side of the longitudinal beam. 1. Clamp 2. Stopper 5.Raise the trailer towing ring from the towing hook. Hono 301 43: Pista © Instrument and Operation iuesay @ 3. Dri Coupling (for trailer) hook « There are coupling device in the rear of the tractor. The Bridge Hose Joint This joint used to connect the hose for transferring 4. Ins, the brake compressed air and the brake control air and tu pressure from the tractor to the trailer. The air , handli supply joint is at the right of the longitudinal direct symmetry plane (look from rear), and the control the ca signal joint is at left. The Bridge Cable Joint 5.H This joint is used to connect the cable for trail transferring the electrical signal to the trailer. outs Towing Hook on To be used to connect the trailer and the tractor together. Ua of tov To outpt Connecting Operation i, Hook oe 1. Adjust the trailer’s towing ring and the towing conn hook to the same height. Zz 2.Pull out the towing hook’s pintle, press the J ce 8.C locking plate, which is on the handle of the ekiarond inf locking pin, back ward and turn the handle con 180° to take the locking pin off forward. L.Hock 2. Ring 44() Instrument and Operation 3. Drive the towing truck back slowly until towing hook connects the towing ring. 4, Insert the lock pin backward and turn the handler 180° in reverse direction. Then lock the cartridge pin. 5. Hang the safe chain of trailer on the safe pin of outside of left and right rails. 6. Insert the plug of trailer cable into the socket of towing truck. 7. Connect the bridge hose connector with output connector of towing truck. When connecting, see clearly between the control connector and air supplying connector. 8. Open the tow separating switches in front of the towing truck connector. nn LEE 45@ Instrument and Operation 9. Turn off the two brake separate switches located at the rear of tractor cab. 10. Be sure the air circuit and electric circuit work normally. 11. Fold the supporter of trailer. 12. Release parking brake and take off the chock. Disconnecting operation 1. Unfold and support the supporter of trailer. 2. Turn off brake separate switch. 3) Disconnect the bridge hoses, then the trailer is braked automatically as the hoses disconnected. Open the air leakage valve of trailer’s air tank and exhaust the air so as to release trailer brake. 4. Loosen the bolts fixing the lock piece and thrust piece, pull the lock bar forward, the thrust piece is blocked in the shaft and then the clip claw is released. Sh Drive the tractor forward slowly so as to separate trailer. 46 1. Close H+NO5-303 2. Open sto for off@ Instrument and Operation ‘The Dumper Dumping Operation Power take-off system operation Parking the truck on the evenness place, Starting the engine, confirming whether the engine works in normal, depressing the clutch pedal completely, making the shift lever in the neutral position, pressing the lock button of the power take-off and turning the operating handle to “engage in” position (for EQ3208G and 3208GH of option of eight speeds gearbox, shifting the shift lever in the low speed, and turn the operating handle of power take-off to the parking power taking off position). And now the power take- off has been connected, releasing the clutch pedal slowly and oil pump of hydraulic system began to start and work. At this time never suddenly depress the accelerator pedal. When it is needed to stop oil pump working, depress the clutch pedal and press the self-lock button of power take-off, then turn the operating handle to stop position. At this time the power of the power take-off has been disconnected and the oil pump stop working, then release the clutch pedal. Dumper lifting operation When the oil pump is in the working condition, press the lifting lock button and turn the operating handle from the middle stop position to the lifting position, then the dumper is being lifted. The oil cylinder automatically leak the oil and stop lifting when the dumper has been lifted at the maximum height. The speed of dumper lifting is increased as the speed of the engine increased. The dumper lifting speed is not too fast and the revolution of engine is not more than 2500r/min to avoid the oil pump over speed. ‘The dumper descending and resetting operation After finished unloading, you should make the dumper descending to its original position at once. Press the lock button of lifting switch and turn the operating handle from the middle stop position to descending position when the dumper will be descended, the dumper go down slowly. When the dumper descending to its position completely, press the lock button of lifting switch again, and turn the operating handle to the middle stop position. Dumper middle stop operation If it is needed to stop lifting, in course of lifting and descending of the dumper, depress the clutch pedal and make the clutch disengaged, and then press the lock button of the lifting switch, tum the operating handle from the lifting position to the middle stop position and release the clutch pedal finally. That realized the middle stop. The power of the power take-off could not disconnected when make middle stop for short time. If making the middle stop for long time, the power of the power take- off should be disconnected and make the oil pump stop working. a EEEEEEEEEEE 47@ Instrument and Operation Descending at heavy load of dumper If the dumper must be descended with heavy load, the above mentioned descending way is not allowed strictly to apply. Otherwise the dumper, chassis frame and carrying system would be badly impacted. At this time, the safety operation carry out as following: ‘Adjust the lifting switch to the mid stop position, turn the throttle handle in counter- clockwise, until the dumper descending slowly. (The throttle has been adjusted to close position and tighten the lock nut when installed. And now take off the cotter pin, loosen the nut and turn the handle again in counter-clockwise). The descending speed of the dumper is determined the throttle opening and other working condition. The operator should go down during the descending and at same time, the operator should go out from the beneath of the dumper when turned the handle. Close the throttle according the opposite procedures after the dumper is down in its position fully. ‘The Dumper Mid stop Operation In the course of the ascending or descending of the dumper, if it is necessary to stop at some angle, it is easy to turn the lifting switch to the mid stop position. Don’t cut the power of the power take-off if the mid stop is for short time. The power of the power take-off must be cut and stop the oil pump working if the mid stop is for long time. Note: 1. Strictly prohibit operating lifting on the uneven ground. 2. When unloading the conglutination goods, the lifting speed of the dumper should be controlled and When the dumper is been lifting to more half (about 40 degree), you should make a so stop the lifting of the dumper that goods would be poured out easily and the front axle would be not jumped. 3. Make sure use the safety bracket to prevent the dumper falling suddenly because of repairing to lift the dumper to top position. 4.In the case of ascending or partial ascending, strictly prohibit drive the dump truck or suddenly descending the full load or half load dumper. Warning: AN 1.Prohibit any person standing under the dumper unsupported with safety bracket 2. Prohibit the any person staying in the area of the dump truck working 3. Prohibit the truck driving when the lifting mechanism and hydraulic system are in working. @ Starti Starti i 2.© Starting and Driving Starting and Driving Starting Engine tt please do daily check. p. Make sure that the transmission gear shift lever is in the neutral position. 3. Turn the key switch to ON position. If your truck equipped with air preheat device, you must pay attention to the air temperature whether preheat indicator HEAT is ON or not. If not, go to the next procedure. If it’s on, turn to the next procedure till the indicator is off. 4. Depress the accelerator and clutch pedals fully, and turn the key switch to the START position to start the engine. 5 After starting the engine, release the key, and gradually release the accelerator pedal till idle running. Be sure to inspect the oil pressure within 15 seconds. 6. When starting the cool engine, depress the accelerator pedal fully and release the pedal before the starter disengage with flywheel. ils. Before running the engine with laden, keep the engine idle for 3 to 5 minutes. Note: A 1.Don’t keep the key in the start position for more than 30 seconds at the time. Continued use of that position will cause the battery to run down. If the engine fails to start, wait 2 minutes before trying again. 2.To ensure safety and reduce the motor load, always depress the clutch pedal when starting the engine. 49© Starting and Driving ssn Starting the engine when the cab tilted ws Pull the parking brake up and turn the key to the switch ON position. 2s Make sure that the gear shift lever is in neutral. Clean up the articles which will fall easily. 38 Clog the wheel with triangle log. 4. Tilt the cab according to specified safety operating procedure. Ss Depress the auxiliary starting push button and the engine will start. 6. When shutting off the engine, pull the engine shut-off cable first. After the engine stops, turn the key from ON to OFF position. Note: 1.Be careful not to touch the transmission’s control lever while the engine is operating and the cab is tilted. 2.Do not put down the cab while the engine is operating. 50 spe clut 3] 4]© Starting and Driving Operation of Clutch No matter shifting from high speed to low speed or from low speed to high speed, depress the clutch twice during driving. After finished operation of clutch, move your foot from the clutch pedal. S SY 4 5 e a H-B-072 1 Depress quickly S.Shift 2.Transmission shift lever in 6.Depress the clutch pedal halfway.swiftly 3.Release quickly then release it slowly 4.Depress quickly 51@ Starting and Driving (aaa @ Braking Operation If you want to stop the truck smoothly, you should operate brake pedal by the following steps: Parl ts Depress the brake pedal for 1/2~1/3 of the pedal travel in the range 1. 25~35m ahead of predetermined parking lot. % Qs Start to slowly release the brake pedal in the range 5~6m ahead of predetermined parking lot. 35 Before the truck arrives at the parking lot, lightly depress the pedal until that makes the truck completely stop. 2. A O Driv fe 1. Se EA) a rs 2) 33 4. 48.003 A Note: 1.If the pedal remains depressed, the truck will come to an abrupt stop in a short distance. 2.Avoid pumping the pedal as it will exhaust the air in the brake chamber, resulting in the truck drifting. 3.For parking, you must use the foot brake. 4.Except emergency braking, please don’t use way of emergency braking to stop the truck, especially driving on the rainy road, use the emergency braking will cause side slide. §.After washing the truck or going through deep water pit, the water may inter the brake drums that will reduce the braking effectiveness. Keep the truck drive at low speed and depress the brake pedal for several - times and make the water vaporized to make the brake working in normal condition. ea — 52,© Starting and Driving ) Parking 1. After driving, temporarily let the engine be at idle, don’t shut-off engine until the engine temperature drop down. Especially after heavier load of engine or high speed driving of the truck, it is not suitable for shut-off the engine right away otherwise it will cause the cylinder pull and turbo-charger damaged. 2. Turn all switches off after shut off the engine, main supply power switch especially. Driving on Slope i When descending a slope, be sure to keep the truck speed within a safe, controllable range by utilizing the engine brake and foot brake. 2. ‘When downshifting, as well as when descending a slope, use care not to allow the engine to exceed Max. speed. 35 Before descending a steep slope or a long gentle slope, apply the brakes and make sure that the brake system functions normally. 4. When driving on a downgrade or shifting into a lower gear, make sure of the truck speed by checking the speedometer. Be careful not to drive over the speed limit for each gear. 53@ Maintenance and Adjustment Maintenance and Adjustment The maintenance of a truck must be conducted periodically and carefully to assure the safe and pleasant driving as well as to extend the service life of the truck. We introduce the brief methods of maintenance and adjustment in common use in this manual. For more details of inspection, adjustment and parts replacement, please contact with the technology service station of DFM corp. Imt, nearby. Checking and Refill Coolant Ls Turn the ignition switch to ON to check the coolant level. If the coolant level warning light is ON, coolant shall be refilled. If the water level can not been seen from the filling hole of water expansion tank, you must refill coolant in it. es Refill coolant from the filling hole of water expansion tank which located at the rear of cab till the coolant level reaches at the 4/5 height of the expansion tank. 3. Check the sealing of filling hol pressure cover and its working condition. Note: 1.Before refilling coolant check engine and radiator for leakage. le 2.Anti-freeze and anti-rusty coolant is recommended, it is prohibited to use tap water in well or river. 54 Drai cool: Air] Insp Ever whe1 oute! indic elem Repl Afte: elem Airl: Vag. @ Maintenance and Adjustment issat Drain Coolant from Radiator Turn off the cock to drain the coolant from coolant system. Air Filter Maintenance pre Inspection and Cleaning interval: Draining cock Every 8000km (4000km in dusty areas); or when the Air Filter warning indicator goes on. The outer element should be cleaned only, but the warn indicator still goes on after cleaning, the inner element should be cleaned. Replacement Interval: After driving 48000km, The inner and outer elements must be replaced at same time. Air Element Replacement 1. Loosen the wing nut and remove the cover assembly, 23 Loosen the wing nut and remove the outer element. Remove the inner element in the same way. 3: Install all the components as the contrary order as above 55@ Maintenance and Adjustment i The method of cleaning element Blow the element from inside with compressed air. Inspect Element Put light into the filter to observe if there is any damage and small holes and check the washer for wear. Replace it with new one if there is something abnormal. A Note: 1. Be sure mounting the element and whirlwind cover, Otherwise the dust may be sucked into the engine to reduce the engine service life. 2.Never use the water or gasoline to wash or brush the element. 3.Cleaning the whirlwind cover to find whether it is damaged. 4, Checking seals as mounting 5. Don’t remove the air filter when driving. 6.Tighten the elements and end cover nut firmly and be sure mount the seal of end cover correctly. Engine Oil First replacement: 1,500 ~~ 2,500km for new truck running-in; Replace interval: Every 8000km The method of checking engine oil level: 1 After the engine is extinguished for 5 minutes, pull out the oil dipstick and clean the marks with clean cloth, then insert it again. 2.Pull the dipstick again and check the oil level. The normal level is between the two marks. If insufficient, 1.Oil dipstick refill the clean oil. If too much, please drain it from the draining cock till it reaches between the two marks. ES 56 1S Repla: 1.Loos and dr is hot. 2.Refi 3.Rep filter < 4.Fill 5.Star of oil idling the oi corre OIF Repl: Repl Rem insta oil fi puts oilf© Maintenance and Adjustment =) Replacement procedure 1.Loose the plug in the bottom of oil pan, and draining over the oil when the engine is hot. 2Refit the plug after cleaning it. 3.Replace the oil filter and clean the oil filter seat. 4.Fill the clean and specified oil. 5,Starting the engine. Inspect the leakage of oil filter and draining oil plug when idling speed. After 5~10 minutes, check the oil level. Be sure to keep the oil level correct. 1.Oilpan __2.Draining hole Oil Filter Replacement interval: 8000km Replacement Procedure: Remove the oil filter by special wrench when installing the oil filter, clean the upper part of the oil filter, fill the filter full with lubricant oil and put some oil on the seal surface, then assemble the oil filter by hand, tighten it % circles by hand. Note: te = 1.Oil filter 2.special spanne 1.Don’t tighten the oil filter with erp tes, eee A the wrench, otherwise the threads will be unformed and the filter will be damaged. 2. When replace a new element, make sure that it confirms to the a} type required for engine. i¢ 57@ Maintenance and Adjustment Mesa Fuel Filter, Water Separator Fuel filter and water separator replacement interval: Every 16,000km Fuel pre-filter replacement interval: Every 24,000km Replacement procedure Remove the fuel filter and fuel filter with water separator or fuel pre-filter by special wrench. When install the new filter, clean the 3.Fuel filter with water separator connecting surface and fill the filter with fuel and tighten them by hand, then tighten them for % circles by hand when the seal touches to the surface. 1.Fuel filter 2.Draining valve Draining Water Separator Extinguished engine and open the draining valve, water and sediment come out. Close the valve when the clean fuel flow out. C=) Note: A 1.Don’t tighten the filters with the wrench, otherwise the threads will be unformed and the filter will be damaged. 2.Tighten the filter only by hand. 3.Don’t open the draining valve fully when draining the water. ac 58Aa @ Maintenance and Adjustment _ essa Bleeding Air from Fuel Line After the following work, bleed air from the fuel system. 1. The oil is not fully filled before the reinstall the filter. Ds Replace injection pump, high pressure fuel line. 3; Replace injection pump, low pressure Button Ble: ding screw fuel line. The way of bleeding air I. Loose the bleeding screw on the fuel inlet pipe, push the button of fuel pump up and down until the fuel without air flow out. Then tighten the screw. The air bleeding operation is now completed. 2s Starting the engine, then loose the nut on injector of engine. Tighten the nut until the air in high-pressure fuel line is over. Note: A 1.Don’t bleeding air when the engine is very hot. 2.Jt is not exceeded for 30 seconds to start the engine every time. The starting interval is at least for 2 minutes. 59© Maintenance and Adjustment Bypass Type of Turbocharger Maintenance 1. Don’t damage the slim pushrod and executor mounted on outside of the turbocharger. 2. Check the clipping spring at one end of the pushrod whether damaged or fallen, and lock nut at middle of the pushrod whether loosen. If loosen, please contact wit DFM service station or agent at once. It is not allowed that dismounting and adjusting the bypass valve mechanism by user. 3. Check seal capability of hose ends at which the clamp fit correctly and the hose has any damage. 4. Be sure use specified brand oil and diesel: After starting the engine within 15 seconds, pay more attention the oil pressure. After starting, warm the engine from low speed to mid speed for 5 minutes, especially for low temperature condition. 5. After the engine operates in heavy load for long tinte, make sure the engine in idle speed for 3~5 minutes before extinguishing the engine. 6. When replace a new bypass type of turbocharger, Be sure fill clean oil to oil intake of turbo- charger, and turn the rotator by hands. 7. Prohibit to apply the operation method of “accelerating -extinguishing-driving” in neutral. Checking and Adjusting of Fuel Advance Angle The engine has been adjusted carefully and confirmed with environment law of the state before it is delivered out of the factory. User never change or adjust it. Only the service station which is appointed by DFM can adjust it. The fuel advantage angle is too small, the engine express powerless, the smoke of free acceleration is concentrated. Check advantage angle of fuel pump. If the angle is too small, adjust the angle to 10 degrees of the crankshaft rotary angle. Static Timing Inspection and Adjustment ‘The engine has been adjusted carefully and confirmed with environment law of the state before it is delivered out of the factory. User never change or a djust it. Only the service station which is appointed by DFM can adjust it. Static timing is set to 1.1 0.1mm before out of the plant. Check the static timing of the fuel pump, If static timing is not in the normal range, please adjust the static timing value to the one set in plant.@ Maintenance and Adjustment Rey Injector Inspection The engine has been adjusted carefully and confirmed with environment law of the state before it is delivered out of the factory. User never change or adjust it. Only the service station which is appointed by DFM can adjust it. If the injector clogged, it will cause bad atomization and smoke of free acccleration and stability become concentrated. Check the injector. If atomizing unwell, replace the injector. 61@ Maintenance and Adjustment essay Valve Clearance Adjustment Intake valve:0.25 + 0.05mm Exhaust valve: 0.51 + 0.05mm If the valve clearance is bigger or smaller than that specified, or the valve noise can be heard during working, the valve clearances must be readjusted at once. Adjust valve clearance under engine cold: !. Dismantle valve cover. 2.Press the timing pin on the engine, rotate the engine slowly by a spanner till the timing pin engaging the timing hole on camshaft gear, the 1* cylinder is at its TDC position. 3. Adjust valve clearance from front to rear in sequence: 4. After the above adjusted, make marks on both the pulley and the timing gear chamber, rotate the engine 360 degrees to make the two marks aligned. 5. Adjust valve clearances as follows: Note: 1. Gear of camshaft 2.Timing pin 3.Gear chamber cover After the TDC of 1% cylinder is found, be sure to turn back the timing pin before adjusting the valve clearances so as not to damage the timing pin. 62 lI® Che The the Adj The pur© Maintenance and Adjustment Check Clutch Fluid The normal fluid level is at 4/5 of height mark. Check the leakage of fluid line before filling. Note: A 1.Don’t use a different quality or brand of fluid. 2.Be sure to use clean clutch fluid. 3.Be careful not to get clutch fluid on any painted surfaces, the paint will be damaged by the fluid. 4.Be careful to seal and reserve. 5. Never allow any dirt or dust to enter the clutch reservoir. Adjusting Clutch The clutch adopt hydraulic operating system of master : pump and booster. The pedal adjusting procedure: Mt Loose the lock nut of master pump push rod, turn SB the push rod in the piston direction. When the \ push rod contacts with the piston, turn the push 2 rod back for 0.2~0.7mm (1/7 ~ 1/2 circle back). ee: Then fasten the lock nut. 2: Adjust the clearance between push rod of booster and piston for 3~5 mm by the same way. 1.Booster 2.master pump 3s After finishing the above adjustments, The free travel of push rods for the master pump and the booster are respectively 20 ~24mm and 17 ~ 21mm. The free travel of clutch pedal should be 30~40mm. 63@ Bleeding Air from Clutch Line The way of bleeding air from clutch line is following: 1. First fill up the oil reservoir of the clutch wit synthetic brake fluid, and keep the air pressure of the air tank at 650kPa.. 2. Take off the anti-dust cover of the booster. Loose the air bleeding screw of the booster, and press the clutch pedal up and down until the air bubbles go out. 3. Fasten the air bleeding screw, and press the clutch pedal up and down. Press down the clutch pedal and loose the screw again so that air can be bled. After this operation, fasten the air bleeding screw and release the clutch pedal. 4. Continue the item 3 of the above procedure until the bleeding screw no longer gives off air. Check Reduction Oil Level First replacement: 1,000~2,500km for new truck running in; Capacity of rear axle: 12L Regular checking interval: Every 4,000km Checking method: Check the oil level by screwing off the plug (1), it should be level with the edge of the inspection hole. If low, top up with the correct oil. Check and clean the vent plug. Replacement Change the reduction oil for per 24,000km. Method of replacement: Change the reduction oil at heating station. Remove the drain plug (2) and drain thoroughly, then clean the drain plug and install it. Top up from the oil filler by screwing off the plug (1). 64 Maintenance and Adjustment 1.Bleeding rubber pipe 2.Bleeding screw 3. Fluid reservoir 1.Oil-filling and checking plug 2.Draining plug I© Maintenance and Adjustment =) Note: A I.never let the dust enter the reduction when refilling oil. 2.Be sure keep the oil level in the normal level position, otherwise it will affect operation. Check and Replace the gear box oil First replacement: 1,000~2,5000km for new truck running in: Regular Inspection: Every 4,000km Checking method: Remove the filling and check plug, the correct oil level is approach the lower edge of the check hole. If insufficient, add oil. At same time clean the vent plug. Replacement interval: Every 24,000km: Replace procedure: Remove the draining plug (2) to drain oil from the gearbox. Clean the magnet in the draining plug which collected sediment in the oil. Fill the new oil through the filling hole till the oil level approaches the edge of the filling hole. Note: 1.Over low oil level will burn the bearing and gears, over high oil level will cause over hot and oil leakage. 2.Keep vent plug venting. 1 Filling plug 2.draining plug 65Low © Maintenance and Adjustment — Wheel Hub Bearing Maintain the hub bearing every 8,000 km interval. Remove the wheel and brake hub and clean them, then lubricate the clearance between the bearing inner washer and the roller. Assembly the hub after lubricating the bearing. Adjustment of Front Wheel Hub Bearing 1. Tighten the lock nut, and turn the hub for 2~3circles to ensure the bearing to be suitable completely. 2. Tighten the lock nut. 3s Allow to turn the lock nut back for 30 degrees and insert the cotter pin and lock it. Adjustment of Rear Wheel Hub bearing Te Tighten adjusting nut and turn the hub, keep the bearing in proper position. ot Tighten the adjusting nut with 5S00N.m torque, then loose the nut 1/4~1/6 turn. BY Lock the locking piece and fasten the screws when the wheel can turn freely without obvious axle clearance and wobbling. 66 1.Wheel hub 2.Anti-wear shim 3.Lock nut ©@ Maintenance and Adjustment ese Adjustment of Brake Regular inspection: Every 8,000km; Check and adjust the clearance of the brake: 0.7mm; Adjusting procedure of brake: 1. Turn the worm shaft by a eye wrench until the brake lining contact with the brake hub, then turn the shaft % circle reverse. At that time the hub can rotates freely. 2. Check the travel of brake chamber pushrod which travel shall be in the range of 25+5mm. Note: Adjusting the rear spring brake: 1.Prohibit changing the travel of pushrod by screwing the connection fork of pushrod of brake chamber. 2.When adjusting the rear brake, the truck must be parked on the even place and keep the pressure of the air tank at 700Pa over. 3. Chock up the rear wheels with triangle logs, then release the parking brake and adjust the clearance of the rear brake. 67© Maintenance and Adjustment Check Travel of Brake Pedal 1 Depress the brake pedal slightly, check its free travel, the normal value is 12~18mm. 2: Do not exist unsmooth phenomenon when depressing the pedal fully. 2 There should be the sound of bleeding when releasing the pedal. Release Spring Brake The automatic functioning of spring brake is caused by the pressure drop in spring brake chamber. First of all, check the pipeline system or valve for air leakage and repair in time. The release method for spring brake is as follows: First remove the rubber dust cap from the release bolt, then loose the nut counter clockwise with spanner-until the release bolt gets out completely, the spring brake is release. Draining Air Tank Drain water from the air tank after truck run, wet air tank specially. Pulling the valve can drain the water. 68 ww woz 2; won© Maintenance and Adjustment ena Adjustment of Front wheel Toe-in Every 16,000km, check and adjust toe-in. The recommended toe-in of this model is 0-2mm ~ a { for radial ply tire and 2~4mm for bias ply tire. ? he Adjustment procedure of toe-in as follows: Wed TDS 1 Park the truck on a even ground and lift Pee yee the front axle by a jack. The front wheels nos oan are put to straight line driving position. 2. Unscrew the clamp bolts at the tie rod. Turn the tie rod with a pipe wrench and the needed value of the toe-in can be adjusted. 3. Make marks on the center of tire surface pattern of left and right, measure the value B at the front of front axle. Then turn the marks to rear and measure the value A. 4. Toe-in is the difference of value A and B (Toe-in =A-B). Tighten the bolts with a clamp ring after toe-in adjusted. 69) Maintenance and Adjustment tiuasadh Inspection and Replacement of Power Steering Fluid Clean the oil reservoir before inspection. Remove the filling cover with oil dipstick assembly, clean the 1 dipstick then reinsert it in the reservoir and take it out again. Observe the oil level. If the oil level is not in the middle position between the two oil level marks, add the oil of the same brand. Checking interval: 4,000km Regular replacement: Every 24,000km re nos Replacement 1. Chock up the rear wheels with triangle logs, The ee shifting lever is put in neutral and lift the front axle by a 1.0il dipstick jack so that the wheels are off the ground. 2.Cover 2.Loose the intake outlet fittings of steering gear, then drain thoroughly and turn the steering wheel left and right at the same time. 3.Re-install the fittings after draining. Remove the reservoir cover and change a new filter. 4. Fill the reservoir with clean oil, then start the engine for a while at the idling speed. Stop the engine and refill it. Repeat the above procedure several times until the oil is filled to specified level. Note: A 1.Never refill oil during the engine running. 2.When running the engine at idling speed, turn the steering wheel left and right in order to bleed the air in the steering system. 3.Be sure extinguish the engine while checking the oil level. 70 ©aN @ Maintenance and Adjustment ies Check Steering Wheel Free-play Check interval: Every 4,000km Keep the steering wheel in the normal position, turn it left and right lightly, check the play. The play should not be over 15” . 7 Make sure that the steering wheel operates normally without shimmying . La) If the free-play is too large, adjust as follows: AR S 1. Check and adjust the bearing clearance of front ore wheel hub. 2. Check tie rod connector for looseness, adjust if necessary. Screw the plug screw to the bottom with special bent wrench, then withdraw 1/4~1/2 turn and lock the plug screw with splint pin. 3y Check the fitting condition between the bail stud cone of tie rod and counter-bore of upper/low arm, tighten the ball stud nut, then screw in the nut 1/3 ~1/2turn at hammering joint until the splint pin is forbidden. 4, Check the spline connector between steering pitman arm and steering gear rocker shaft and its tightening bolt for looseness. 5, Check the rocker arm shaft of steering gear and rack piston for engagement and adjust. 71@ Maintenance and Adjustment Battery Inspection and Maintenance Before servicing the electric system, be sure to turn off the electrical isolator switch. Inspect Battery Electrolyte Checking interval: Checking battery electrolyte for 4,000kmm. The liquid should be 15 to 20 mm above the ceil plates. If it is lower than that, add distilled water up to the 1. Electrolyte specified level and charge the battery for at least 30 minutes until the water is well mixed with the battery liquid. Rep Rep 2.Pole plate Check Gravity of Electrolyte Checking interval: Check the electrolyte per 16,000km. Check the specific gravity by densimeter , the reading should be in the 1.26 to 1.265 (electrolyte temperature 20°C). If the specific gravity is below 1.22, charge the battery. 1 Float 2.Read horizontally Rep Fuse When replacing fuses, be sure to use of the specified rating. If fuses are blown readily after they have been replaced, the cause should be determined and the problem repaired. Contact the nearest service station. Note: A Never use common conductor lines or improper fuse instead of rating one. 72@) Maintenance and Adjustment esp Replacing Bulb Replace bulb of front combination light 1,Steering signal light 2. Width indicating light Replacing bulb of headlight 73@ Maintenance and Adjustment =) Replacing bulb of front fog light Replacing bulb of rear combination light and rear fog light 1.Rear lamp 2.Rear brake lamp L.H” 3.Steering light L.H 4.Rear fog light 5.Rear brake lamp R.H 6.Steering light. 7.Licence light a 74 i) Re Sir bo© Maintenance and Adjustment ijessany Replacing bulb of side steering signal lamp Side reflector and side mark lamp Equipped with fence rails and reflectors at both sides Front width lamp 1208 107 HBA3t 1.Side fence rail 1.Front width indicating lamp 15© Maintenance and Adjustment esa @ Rear width lamp Dim The the s 1.Th angl 2.Th direc and L.Rear width lamp _2. Fire extinguisher Dist 1.Tt Light Adjusting Methed a General Adjustment ci he Stop truck on dark, flat road surface, place light switch in dim light, turn the 170; adjusting screw of outside headlight and adjust dim light shape. After that adjustment, place light switch in distance light, screen the adjusted headlight 3.Be with paperboard, turn the adjusting screw of inside auxiliary headlight and si ide adjust distance light shape. shal Standard Adjustment Preparations Fro 1s Light adjusting ground shall be smooth and the applied screen shalt cate be perpendicular to the ground. Hae 2. The truck is without load with a driver, tire pressure shall be normai. be 3: The truck is perpendicular to screen and the headlight reference ny center is 10m away from screen. (De 4. Drawn a horizontal reference line on the screen, its height shall be vet equal to the ground clearance of headlight center, the height is ro indicated as “H’’. According to first adjust the dim light, then the F distance light. 16@ Dim light The requirement of the dim light beam on the screen: 1.The light beam light-and shade cut-off line angle or midpoint is 0.6H — 0.8H. 2.The amount of offset in horizontal direction can not exceed 170mm for left side and 350mm for right side. Distance light 1.The height of light beam center is 0.8H — 0.95H. 2.Leftward offset of left side distance light in horizontal position shall be not more than 170mm, rightward offset shall be not more than 350mm. 3.Both leftward and rightward offset of right side distance light in horizontal direction shall be not more than350mm. Front fog light Acclear horizontal brightness-shade cut-off line with width not less than 2250mm shall be produced on the screen 25m before the front fog light reference center. (Determining for horizontal and vertical reference line on the screen is the same as procedures in preparations) 71 anes Note: ‘A: Left headlamp upper beam. Leftward offset< 100mm, rightward offset <350mm B: Right headlamp upper beam. Both left and right offset < 350mm. C and I: Left and right headlamps. Left offset < 100mm and right offset < 350mm D: Reference line E: Lamps height off ground F: Headlamp beam center (the most bright point) G: Test screen H: Turning angle of headlamp beam brightness- shade cut-off line@ Maintenance and Adjustment Subsidiary Power Starting When the battery is not charged, the engine starts difficulty during the operation. Using a subsidiary battery starting in order to start engine. Connecting procedure: 1 Extinguish the engine of the truck which battery is good. 2. The one end connecting assistant battery cable (red) is connected with the positive terminal of discharged battery. The other end is connected with positive terminal of charged battery. The one end of other connecting assistant battery cable (black) is connected with negative terminal of charged battery, the other end is connected with the chassis frame of discharged battery. Then you must be away from the battery as far as possible. 3s After connecting the cables, start the engine of discharged battery. If the ambient temperature is too low to start. Run the engine of charged battery for several minutes first, then start the engine of discharged battery. 4. After the engine starts, disconnect the cable according to the opposite procedure of connecting steps. 78 Wes 118 1, Battery with charge 2. Battery without charge 3. Chassis frame Cha Ope 1W choc 2. the t 3. Ja jack 4.D 5. If posi! jack. aw, © Maintenance and Adjustment Nasa Tyre Inflation The air release valve (1) is fixed on the air tank. Operating steps are as follows: 1. When inflating tire, take off the wing nut, connect the wing nut of inflation hose with the air release valve and then inflate the tire. 2. Start the engine, air compressor begin to work and keep engine run at 1,000r/min during inflation process. 1.Inflation hose 2. Air take-off valve 3. After the air pressure in the air reservoir rises to 3.Unload valve 650kPa. The other end of the inflation hose is AME ryer, connected to tyre valve hole and check it with air- pressure gauge, achieved specific value for the tyre pressure . 4. Dismounting the inflation hose, screw casing cap of obtaining valve and then stop the engine. Change the Tyre Remove Tyre Operating steps are as follows: 1. When removing front wheel (rear wheel), first chock up the front and rear wheels. 2. Loose the wheel nuts with the socket wrench of the tools by truck. 3. Jack up the one end of the axle with the hydraulic jack, make the wheel not contact the ground. 4, Disassembling wheel nut. 5. If this is dual tires, drop the axle to original position at that time. Then loose the inner wheel nut, jack up the axle again until the wheel can’t contact to the ground. 79@ Maintenance and Adjustment 6. Disassembling the inner wheel nuts, then disassembly inside wheel tyre. Note: 1.The right wheel nut is right thread, the A left nut is right thread, the left mut is the left thread. 2.Clean outside thread of the wheel bolts, and apply a little lubricating grease on it. Remounting Tyre 1. Put the wheel rim bolt into wheel hub bolt with the crowbar. 2. Adjusting wheel hub bolt to the central position of the bolt hole screw tyre nut. 3. Drop the jack slowly to make tyre contact to the ground. 4,Tightening the wheel nut by specified torque at three times. 5, If it is dual tire, re-jack the axle to make the tyre not contact to the ground, Remounting the outside tyre according to steps 1,2,3 and 4. 6. If remounting outside tyre only, tighten inner tyre nut according to the specified torque. Then remounting outside tyre. Check Tyre Pressure and Tyre Surface 1. Check whether each tyre’s pressure meets the specification. If not, need to be inflated. 2. Check whether there is any object hanging on the tyre surface. If there is, remove it. 3.Check the depth of the tyre checker. If the depth is Jower than 1.6mm (lower than 2.4mm in high speed way), the tyre needs to be replaced. When the tyre is measured at least measure six points along the tyre’s circumference. SS 80@ Maintenance and Adjustment ey . Mounting and Dismounting of the Spare Tyre 1. Remove the safety long nut(1), turn propeller lever in counter-clockwise by a special wrench, let spare tyre downward, then take tyre holder out. 2. Mount the spare tyre according to the opposite steps of dismounting steps. Interchanging of the Wheel ‘When the truck has run for 16,000km, the wheel s must be interchanged according to the specified in figure. The principle of interchanging the wheels as follows: 1.External diameter difference of dual tyre in the rear axle is not more than 12mm. Smaller external wheel is fitted inside. oa 2. The front wheel should be fitted the type, balancing and a little wear type. 3. After interchanging, the opposite direction of the rotation should be to that before interchanging. 4. New tyre must be used in pairs. 5. The same size grade tyre should be equipped in the same axle, or cause in braking deviation in direction, the rotation of body and steering can be not controlled. 6.Check whether there is the thread in the wheel hub bolt and wheel nut. If there is scar, no matter which is worn, change in pairs for safety, because another may be damaged. 7.Check the contact surface of the wheel rim and fixing hole, if there is a deformation or damage, it should be changed. If the contact surface of the wheel nut has also been damaged, it should be changed too. 8.Check the wheel rim, if it has crack, it should be replaced. 1 .Long screw socket 2.Driving lever 3. Washer 4.225989 81@ Maintenance and Adjustment es @ JZ Ta 9: When remounting the dual tyre, the Th valve pins of inside and outside wheels pe must be staggered for inflator easy. in per be Lifting Mechanism Hydraulic Pressure Oil Ch Replacement interval: a Th After it has left fro 300 times during running- Ie in, The hydraulic oil should be replaced. After 2 that, replace the oil per 12,000km. 4: Replacement method as follows: 4. Ie When carry out replacing oil, raise the dumper to top position, 5. and support the dumper with the safe holder to protect the dumper fall down automatically. 2s Loose the draining plug of oil reservoir and oil intake fitting of oil cylinder and drain the used oil completely. After cleaning the draining plug, screw it on again. Then fill the clear oil form the upper filling open until the oil level achieves to the level 1 line on the dipstick. oF Start the engine, make the tilting system fill with the new oil. Move safe holder. After making the dumper descending lifting the dumper for two times until the lifting mechanism work normally. Strictly prohibit man standing under the dumper during its lifting. If necessary to work under the dumper, make sure support the dumper with safety bracket. 82,© Tables Maintenance Schedule esa Tables of Maintenance Schedule The maintenance schedule shows checking items and expiration of the first period of maintenance. After that, except not carry out maintenance of Tunning in , the second period of maintenance circulate according to the first. The period of maintenance should be performed either at number of kilometers or months, whichever comes first. Check and Maintenance Interval The meaning of marks: A Mileage (x1000km) B month %* Maintenance items at normal driving yr Running-in maintenance items /\Running-in maintenance mileage (1500—2500km) Note: Customers should lessen the inspection and maintenance intervals if the surroundings are sever. Never prolong the intervals. 1 BS Engine Check and Maintenance Item Clean engine ass'y (Check and adjust the fan belt (Check the coolant for leakage (Check leakage of engine oil (Check cleanliness and level (Check leakage of fuel Remove sediment of fuel pre-filter (Check ace. Performance and exhaust Replace the engine oil Replace engine oil filter assembly (Check and clean the air filter element 3) E) 2b] 2b) ot] +L Oe} a si>lsI51 15@ ‘Replace fuel filter and water separator Replace fuel pre-filter [Check \adjust valves clearance Fasten the bolts of cylinder head and other bolts Replace air filter clement ‘Check radiator ‘Check function of thermostat Clean the engine cooling system Check injecting pressure and timing of the injector Check the fuel pump Check the compressing pressure of cylinder Note: 1.If the warning signal appears before the checking and replacing period, clean or replace it in time. 84EE EE Kk [=| * aes ae | |] fe fae [ie fe [oe | x ale [eal Check control mechanism for looseness. or damage Check bearings for proper function 85© Tables Maintenance Schedule iussay Brake System Check and Maintenance Item 4Check brake free travel T Check clearance of brake dram and lining [> | [Check the tightness of brake bottom plate fx | [x] [| | Replace itif necessary [ae Jeng Bek puma ing for | Check the air dryer for proper function i Check and maintain the valves -- Steering System (Check steering gear for leakage tH [Check steering wheel fro free play [ax | | | Check brake dram and lining for wearing. PEE {Check air compressor for proper function E+ (Check connecting and tightness * a 2 a I HI * + ra re \ Check ball studs tightness of steering drag | vr |e [a] a [a [a] |e] | a] oe |e link and tie rod 86# Check inner leakage and gear clearance of Steering gear Check and Maintenance Item [Check U-boll for loosen Check Leaf spring for damage Check function of shock absorber, Replace it if necessary Check clamp of leaf spring for looseness and deformationTables Maintenance Schedule Propeller Shaft Check and Maintenance Item [Check propeller shaft joints for loosen Check Spider bearing for slacking =e x lk Elect Clean propeller for offset B Check propeller spline for wear Axle and Wheel GEE ‘Check bolts of half shaft, wheel nut for tightness ‘Check tires inflation pressure (Check tire worn abnormally (Check rim ass’y for damage and {deformation (Check, adjust clearance hub and greased it |Check half shaft bolts for loosen Replace mid/rear reduction oil Check mid/rear reduction and bearings 88© Tables Maintenance Schedule Electrical System p 24] 281 32] 36] 40 Check and Maintenance Item [pals] 2136] 213 [4 [5 6 |7 Js [9 Jiofarfi2 ‘Check generator function * ae wll lal Kal * wie Check battery electrolyte level 1 Check hamess connecting condition 1 Check lights, relays working state Chet electrolyte specific gravity Towing Seat Check and Maintenance Item Check srews tightening of seat with Bottom plate and bottor plate with frame Check wear of saddle bearing ‘Check wear of saddle bearing rubber bush Check wear of: tractor pin and pin locking plate 89@ Tables Maintenance Schedule =) © Other Check and Maintenance Item Check frame rivets for looseness Check cab tilting device function Check cab connections Check, liquid system for leakage and seals liquid sys Be 90© Tables Maintenance Schedule Periodic Parts Replacement Periodic replacement are those deteriorate with lapse of time. These parts are mainly rubber parts such as brake hoses, fuel hoses. It’s difficult to predict the safety of these parts when checking them with the method used in the usual periodic inspection. Hence, applicable parts must be replaced whether they appear to be unable or not. Replacing period (Year) [+] [Rubber hoses of power steering hydraulic system | % | | 7 Rubber parts of valves in the brake system Rubber hoses of brake ane Rubber hoses of air compressor Rubber hoses of clutch control linkage All oil pipes of lifting mechanism Fuel hoses: Grease Lubrication Interval Greasing should be performed periodically. Wipe all dust and dirt from the grease nipples and other points which are needed to be lubricated, and then apply grease. After greasing, wipe off any excess grease. Be sure to put the caps back on if so equipped. This schedule should be kept the dams as maintenance schedule. The meaning of marks: A Total mileage (x!000km) B Months 4 Maintenance items in normal driving vy Running-in maintenance items 4 Running-in maintenance mileage (1,500-2500km) 91% Check and Maintenance Items E Steering drag link and tie rod ball studs King pin of steering knuckle Steering propeller shaft slip yoke and spider bearing * |e] Front leaf spring pin and shackle pin Dum Propeller shaft mediate bearing lal fel [a Pape faye ele] Pe] “t + poe | Oe Le Propeller shaft slip yoke and spider Oil cylinder piston connector Oil cylinder bracket Rotating shaft at rear of cargo body ‘Adjusting arm of front/rear brake + | lelelel % ee ep oe pe] % | + fella + [oe foe] oe fel e) Pee HR] H LH] He] H PEL [+ [elefe] + [epee pepe To Hub bearings of wheels Pepe De Pe Pepa [oe +) ot fot p ep | oe ‘Tilting lock mechanism of cab Alternator bearings ele] ef oe |e pepe pH] He | HLH Starter bearings Door hinges Separating bearing of clutch a) foe [oe [re pe] oe |e | RP ee] oe | me] me] Le Door lock, window glass regulator mechanism and speedometer flexible shaft 92 *© Tables Maintenance Schedule Dumping Section Greasing location Greasing point Greasing period Rod end of piston in cylinder 1 Every week Lower cylinder bracket Every week Drag arm shaft Every week Lifting shaft Tilting shait Every week Every week ‘Turning shaft of rear fender Every week Locking hook of rear fender Every week@ Tables Maintenance Schedule wees Dumping Section Greasing location Greasing point Greasing period Rod end of piston in cylinder Lower cylinder bracket Lifting shaft Turning shaft of rear fender 1 Er Locking hook of rear fender 94© Service Data Service Data Engine Intake valve clearance (at cold state) Exhaust valve clearance (at cold state) The lowest oil pressure of engine at idle speed 0.5mm 69kPa 0.25inm, fess | ‘The lowest oil pressure of engine at normal speed 207kPa Pressure control valve opening pressure of engine lube oil 414kPa Ey By-pass valve opening pressure difference of oil filter 138KPa rotational speed 750 100r/min 95@ Service Data Chassis Steering wheel free play Radial ply tire Toe-in Bias ply tire [Clutch pedal free travel Push rod travel of master pump Clutch booster rod travel Front brake chamber push rod travel Rear brake chamber push rod travel Clearance between front and rear brake lining:and brake drum Pulling force of front wheel hub bearing after being adjusted (at tire nut) Pulling force of mid/rear wheel hub bearing after being adjusted at (tire nut) ‘Torsional force of final reduction assembly | At the connecting flange bolt hole after being adjusted At the driven wheel bolt Pre-load of driving gear bearing (rear axle at | Not including oil seal resistance connecting flange bolt hole) Clearance of the differential gear Back/forward adjusting distance of the steering wheel 96,© Service Data oa Tightening Torque Tightening position Tightening torque (N.m) Fan fixing bolts 24 24 1% step, 40(all bolts); 2» step, 90(all. bolts); 3" step, T2GaR tong bole AF siesPhurs GO CAT battss foottPhots 5 ei 1 Mal bolts); 2! step, 119(all bolts); 3er step, [Generator low base fixing bolts 24 [Exhaust manifold fixing bolts 43 (Generator upper base fixing bolts 43 Fixing bolts between flywheel and Seana ve 137 ll bolts); 2" step, 90(all bolts); 3 step, /Main bearing cap bolts Timing gear lock nuts of injecting pump Injecting pump bolts Fitting for fuel supply pipe and filter Injecting pump fixing bolts Injector fixing bolts Pressure limit valve plug ‘Starter fixing boltsService Data Chassis ‘Tightening position Fron! tyre fixing nuts Tightening torque (Nm) 412-480 Connecting bolts for steering gear and stecring universall joint yoke 30-50 Connecting stud for upper steering knuckle arm and steering knuckle 216 Lower steering knuckle arm tightening nut 274-343 Steering knuckle thrust pin lock nut 24-40 ‘Connecting nut for lower knuckle arma and knuckle pin 245-340 Tie rod clamping nut Locking bolt and nuts for pitchman arm and pitchman shaft 38-42. 407-343 King pin upper caver fixing nut Draggling ball-pin fixing nut Stecring gear bracket fixing bolts and nuts (with upper part of frame) Steering gear bracket fixing bolts and nuts (with lower part of frame) Front and rear brake lining shaft lock bolts Brake chamber fixing nut Rear tire inner/outer nuts Rear tire fixing bolt tightening nut Reduction oil level checking bolt Rear axle housing oil drain plug 40-59 af 250-310 220-250. 420-450 50-70 170-200. 300-420 300-420 130-150 130-150 Rear brake plate fixing bolt 200-250 Axle shaft tightening bolts 140-180© Service Data Rear axle drive gear bearing cap tightening bolts 120-140 Rear axle differential carrier tightening bolts Reduction driving gear nuts of forward rear axle Rear axle housing fixing bolts Rear reduction drive gear flange fork loc nuts Propeller shaft spider flange yoke connecting nuts 220-280 211-240 Main shaft drive bearing nuts Main shaft rear bearing cap screw 339-407 Shack absorber and upper bracket fixing nuts Shock absorber lower pin and bracket fixing nuts 134-167 Shock absorber with lower pin fixing nuts Capacity Data Engine oil pan (EQB180-20) CF-4 1S W/40 134-167 Capacity (L) Engine lubricant system (EQB 180-20) | CF-4 15W/40 [Engine oil pan (EQB210-20) [ce-4 1swia0 |Engine lubricant system (EQB210-20) CF-4 15W/40, Engine oil pan (EQB235-20) CF-4 15W/40 Engine lubricant system (EQB235-20) CR-4 15W/40 Engine oil pan (YC6105ZQL) CF-4 15/40 Engine lubricant system (YC610SZQL) CF-4 1SW/40 ‘Diesel oil tank (For other models except }EQ3141G7D, EQ4141G&D) Diesel oil Disc nk iy aQTGTDO [Beton 99Service Data © © i) Location Type Diesel oif tank (only for EQ3141G7D) | Diesel oil c : : 85W/90 MT-I oil for hand operating : Transmission case ‘gear box or GL-4 mid load gear oil 6f U Yehicle a 85WI9OGL-5 heavy load gear oil of d vehicle a | Power steering gear CF-4 15 W/40 Clutch oil reservoir V-3 (HZY3) compound brake fluid Z Oil reservoir of hydraulic lifting system | Hydraulic fluid a aging coding dystent ‘Ati freeze and ant-rust uid for long F - U Location A Inner side (24-75770W y Headlight 1 a Outer side TLQ24-75770W = Front 1—70W Fog light qlee ioe mel He Front combination light Sooner ee of 0 Outline light Side turning signal light Rear tuming signal light “= Tail light Qr24—21/5W Rear combination light Rear backup light License lamp Figure indicating lamp R s a Side mark lamp QT24—5W. & wae : z P Warming & indicating light Qru4—12W Instrument Instrument light QT24—3W© Service Data Oil and Lubricating Grease Engine oil and steering gear lubricating oil Use 15W/40 CF-4 grade diesel oil. According to local air temperature, customer can choose CF grade lubricating oil with different viscosity level. The recommended ambient temperature range is as shown in fig. Transmission Lubricating Oil Gear box use 85W/90 manual gearbox oil. According to local air temperature, customer can choose vehicle gear oil above GL-4 grade with different viscosity level Fuel Use qualified light diesel oil specified in GB-87 Standard. According to local air temperature, customer can choose qualified light diesel oil with different brand. Recommended temperature range: O# light diesel oil Use above ambient temperature 4c -10# light diesel oil Use above ambient temperature 5c -20# light diesel oil Use above ambient temperature -Sc ~ -14¢ -35# light diesel oil Use above ambient temperature -14e ~ -29¢ -50# light diesel oil Use above ambient temperature -29¢e~ -44c Rear axle Oil ‘Sulfur-phosphorus type (GL-5) heavy load gear oil is recommended for the rear axle. According to local air temperature, customer can choose gear oil above GL-5 grade with different viscosity level. Lubricating Grease Li-base lubricating grease commonly used in vehicle for wheel hubs and other places to be lubricated is recommended. i 101‘ aX © Service Data iyssany Clutch Booster Fluid Use the pointed DFHlof DONGFENG brand compound brake fluid or DOT3 of DONGFENG brand brake fluid. Warning: A 1.Don’t mix with brake fluid made by different manufacture. 2.Don’t mix with different type of brake fluid made by same manufacture. Engine Cooling Fluid: Make sure that customer should always use special anti-freeze and anti- corrosion fluid, never substitute well, river water or head water for it. DONGFENG serial ever effective anti-corrosion fluid used in DONGFENG truck for long time. Warning: LN 1.The freezing point of the anti-freeze fluid used in the especial cold areas should be 10c lower than the lowest local ambient temperature. 2.Don’t mix with the different type of anti-freeze and anti corrosion fluid. Dumping Hydraulic Oil Use the specified HL, H¥32 oil. Use HR32 or N32 Low freezing fluid in special cold areas. 102| @ Main Specification ey Mass Data Mass data (kg) EQ1141G7D | EQ1141G7D2 bee a Permitted total weight of trailer 8000 Gross weight 6100 omg a | Vehicle curb Front axle load 3000 as Front axle load Gross vehicle. weight Rear axle load romerwaen | tao 0 Rated loadage Permitted total weight of trailer ee Gross weight ~ Complete Vehicle curb | Front axle load mass Rear axle load | | Gross vehicle : Rear axle load weight Gross weight@ Main Specification =) Mass data (kg) Rated loadage i) EQUL46K 8000 EQU4K2 Permitted total weight of trailer Gross weight 5955 Complete Vehicle curb Front axle load 3055 mass Rear axle load 2900 Front axle load 4580 4600 Gross v Rear axle load 9750 14350 weigl Gross weight ood Mass data (kg) EQI168G7D_ | EQI168G7D1 | EQ1168G7D2 | EQUI68K7D Rated loadage | 9705 9900 Permitted total weight of trailer | ! / 7 b ccsiiie Gross weight | | 5905 Vehicle curb | Front axle toad 3000 + mass Rear axle load 2905 Gis Front axle load vehicle | Rear axle load weight Gross weight 104| @ Main Specification ea Mass data (kg)\ Rated loadage Gross weight Complete Vehicle Front axle load curb mass Rear axle load Front axle load Gross vehicle weight Rear axle load Gross weight Mass data (kg) EQ441G7D| EQ4146G | EQ4146V 17000, Permitted total weight of trailer 17000 22350 25600 5355 Complete Vehicle ("on axle load eae curb mass Rear axle load Front axle load cat [pera | ghee [eared Ta Permitted saddle max. loadage of ae semi-trailer 105@ Main Specification Dimension Data Dimension data (mm) Overall length Overall height Overall width Wheelbase Length Inner size of cargo body Front axle Rear axle EQUI41G7D 7730 2470 EQUI41G7D2 8530 2470 EQU46G 7730 8530 2470 2470 EQUI46G2 Front overhang Overhang Rear overhang Approach angle 2285 Departure angle Min. ground clearance 106© Main Specification Dimension data (mm)\ BQI46K | FQI46K2 | EQ3168G7D | EQ31466 Overall length 7690 8490 6520 + 6520 Overall height 2470 2470 2470 2470 Overall width 2790 2830 2890 2890,2970 i Wheelbase 4500 5000 | 3800 ' = “3 fs aks : 6 Length 5300 6100. 4127 N27 Inner size of cargo Height 2294 2294 2300 2300 body = Width 550 550 600 600 Wheel Front axle 1940 1940 1940. 1940 ele + tread Rear axle 1360 1860 1860 1360 Front overhang 1205 1205 1245 1245 Overhang alors Rear overhang 1985 2285, 1475 1475, feat Approach angle 34 a 34" 4 Departure angle 18° ie 36" 36° Min. ground clearance 248 248, 248 248 107@ Dimension data (mm) Main Specification BQI168G7D EQUI68G7D1 EQ1168G7D2 Zo oS EQU168K7D. 7730 8990 8530,89320 Overall height 2470 2470 2470 Overall width yy. 2790,3200, 3350 2880,3200 3350 2830,3200 3350 Wheelbase “al 4500 5600 5000 Length Inner size 5300 6600 6100,6500 ofcargo | Height 2294 body Width 550,600 Front axle 1940 Rear axle 1860 Front overhang [ 1245 Rear overhang. 2285,2685 Mi Approach angle Departure angle Min. ground clearance 108© Main Specification es Dimension data (mm) BQ4141G7D EQ4146Vv | EQ4146w Overall length 5610,5670 5650 Overall height 2470 2470 ‘Overall width 3200,3350 ‘Wheelbase Wheel. Front axle tread Rear axle Overhang | Front overhang Rear overhang Approach angle Departure angle Min. ground clearance 109@ Main Specification Performance Data Performance data Max. speed (km/h) Max. gradcabiliry (4) Fuel consumption (1,/100km) EQU4IGID | EQU41G7D2 EQU46G | FQU46G7D2 90 Min. speed a direct shift (km/h) s¢ without lade: Parking brake sl (4), Min. turning diameter (m) | Performance data BQUI4OK | RQULM6K2 Max. gradeability (%) Fuel consumption (L./100km) Min, speed at direct shife (km/h) Parking brake slope without laden Min. turning diameter (m) (%), 110© Main Specification Performance data\, EQUI68G7D | EQU168G7Di EQUI68G7D2 Max. gradeability (%) Fuel consumption (L,/100km) Min. speed at direct shift (km/h) Parking brake slope without laden () Min. turning diameter (m) Performance data EQU68K7D } EQ3168G7D ‘Max. speed (km/h) Max. gradeability (4) Fuel consumption (L/100km) ‘Min, speed at direct shift (km/h) Packing brake slope without laden (%) Min. turning diameter (m) ill EQ3146G© Performance data Max. speed (km/h) Max. pradeability (%) Fuel consumption (L/100km) /Min. speed at direct shift (km/h) Parking brake slope without laden (%) ‘Min. turning diameter (mn) Note: 1.The vehicle curb mass includes oil, coolant, fuel, spare wheel and tools. 2.The vehicle full laden mass of £Q1146K,EQ1146K2,EQ1146G7D1,EQ1168G7D2, EQ1168K7D includes three persons weight in cabin (195kg) 3.Min. turning diameter is measured by track center of front outer wheel. 4.Front wheel tread is measured by center of touching ground. Rear wheel tread is measured by center of dual tyres. 5.Min, ground clearance is the rear axle ground clearance in full laden. 6.Overall height of complete vehicle is measured by front bumper without load. 7.Max. gradeability is the gradeability without trailer in full load. 112@ Engine awe 1 Qussany Assemblies Structure = EQB210-20 engine Type Water cooling, 6 cylinder in line, air cooling turbocharger diesel engine Mode Rated speed EQB210-20 2500 r/min, Rated power 1S5SkW(2500r/min) Max. torque 7OON.m(1500r/min) Bore x stroke 102mm x 120mm Displacement Compressed ratio Injecting order S.88L 17.3:1 1-5-3-6-2-4 Fucl: Summer: O# light dicsel oil; Winter: Use the proper light oil According to local ambient Type\ Mode temperature. EQB180-20 engine Water cooling, 6 cylinder in line, turbocharger diesel engine EQB180-20 Rated speed 2500 r/min, Rated power Max. torque 132kW(2500r/min) 610N.m(15001/min), Bore x stroke Displacement Compressed ratio Injecting order 102mm x 120mm 5.88L, 17.3:1 1-5-3-6-2-4 Fuel: Summer: Oi light diesel oil; Winter: Use the proper light oil According to local ambient temperature,© Assemblies Structure ah EQB235-20 engine Water cooling, 6 cylinder in line, air cooling turbocharger diesel engine £QB235-20 Rated speed 2500 r/min. Rated power 173kW(25001/min) Max. torque 800N.m(1400-1600r/min) = Injecting order 1-5-3-6-2-4 Frick: Summer OF Hight diesel oi, Winte: Ube the proper light oil According to local ambient YC6J190-20 engine Water cooling, 6 cylinder in line, air cooling turbocharger diesel engine 2 n Bae Compressed ratio 17.5:1 Injecting order 1-5-3-6-2-4 Fuel: Summer: 0# light diesel oil; Winey ee he pres light oil According to local ambient tal) feted Pope ar ew © Assemblies Structure Gussany Clutch Single dry plate, diameter 380mm, hydraulic control with air booster Transmission case Mechanical six speed with remote double lever control. The ratio of each speed shows as follows: Propeller Open type and spider universal joint combined with spider needle bearing, sliding spline shaft and mediate bearing support. Front Axle Forged-steel piece with H-beam section, two-stage dropping, [er canoe TERETE] Caster 1°252'3 7} Inner wheel Front wheel alignment Max. turing angle of front wheel ET EN Tae Outer wheel 115@ Assemblies Structure Driving Ax? 6 driving. integral press-weld axle housing and fully floating Type: tande™ with 6 whee! assembly per truck. EQ3141G7D and £Q3141G7DH ‘equipped with bias ply tyres. Other models are equipped with radial ply , The bias ply tyre is for option. | Tiresize: 10.00R20 or 10.00-20 16PR | Jnflation pressure: 770kPa for radial ply tyre; 670kPa for bias ply tyre. ‘Suspension Front Suspension Rear suspension EQ1141G7D,EQ1141G7D2, EQI146G,EQ1146G2,EQ1146K, 10 pieces of main leaf spring EQUI46K2,EQ1146G7D,EQI168G | _ 8 pieces of leaf spring and’8 pieces of subsidiary leaf 7D1,EQI168G7D2,EQ1168K7D, spring EQ3168G7D,EQ3146G. 10 pieces of main leaf spring EQUI4IG7D,EQ41466,EQ4146V, | Pieces of leaf spring | and 3 pieces of subsidiary leaf EQ446W spring Chassis Frame The chassis frame assembly is press-rivet structure, The frame of EQ1141G7D3,EQ1146F is straight longitudinal rail of half section. Other model frame is straight longitudinal section of equal section. Added enforcing steel plate in the longitudinal rail in left front of which mounted a emergency towing hook. The frame of EQ1168 series are riveted with two Pieces of same section U type longitudinal rail and some beams, Equipped with subsidiary frame and emergency towing hooks at front and rear end of main frame. The subsidiary frame is made of two straight longitudinal rail which was pressed in U type. es 116 Steer Doub front colun shaft. and re down, Brake § Dual cir Main eq Service | with loa controlle Subsidia air. Electric: Adopt 24© Assemblies Structure Steering System Double spoke steering type wheel, trapezoid linkage mechanism behind front axle and power steering system. Steering drive shaft with a steering- column and two spider universal joints can be combined by steering drive shaft. Steering drive shaft and splined tube shaft include steering drive shaft and relative slip. Steering wheel can be adjusted forward and backward, up down. Steering gear is an integral power steering gear with blade pump. Brake System Dual circuit brake system “Main equipment: Air compressor, three air tanks; Valves and hoses and so on; Service brake: Dual circuit, stepping directly braking valve, d pe brake with loading and sensing valves; Parking brake: Rear wheels spring brake _ - controlled by hand controlling valve, actuated on the rear wheels; | Subsidiary brake: Engine exhaust brake operated by butterfly valveelectrical air. | Electrical System Adopt 24V line system negative earthing. 117@ Assemblies Structure Instrument: Speedometer, tachometer, voltmeter, water temperature gauge, fuel gauge, oil pressure gauge, compressed air gauge, (2 pieces). Lamps: Head light (2pieces), front combined light (2 pieces), fog light (2 pieces), side turning signal light (2 pieces), tai lamp (2 pieces), back-up light(1 piece), license lamp (1 piece), Inspecting Jamp (1 piece) and width lamps and so on.. Indicator and warning light: Turning indicator, charging insufficient lamp, Parking indicator, exhaust brake lamp, water temperature over heat and water level lower alarm, insufficient air pressure alarm, oil pressure insufficient warning lamp, back-up alarm, electric horn (2 pieces), air horn. Switch: Main power switch, ignition switch, combination switch, assistant starting switch, power take-off and dumping switch. Cab Cab-over engine can turn over. Three seats with sleeper. The driver’s seat can be adjusted, the driver’s seat back angle can be adjusted forward and backward. The sleeper is behind the rear row. There is a blanket, glove box, quartz clock, cigarette lighter, inner back sight mirror, sun visor, and window curtain support in the cab. Both doors have locks, and the door glass can be lifted. The glass of triangle window and back sight mirror can be opened. Electric wiper and washer are fitted to the front windshield and back sight mirror is fitted on the outside of the door. Cab Heater and Air Conditioner The cab is equipped with both heater and air conditioner. Air conditioner adopt the R134a cooling agent of environmental protection air conditioner system instead of fluorin. ae 118 Laz ane RAss ie @ Assemblies Structure essay Cargo body The cargo body is metal-wood structure with window which is covered with widen cover for repairing gear box on the floor between the first and second beam of the frame. Side and rear boards can turn down. Front board has safety fence; The dumper of dump truck is metal structure, rear opening type cargo body. Front board with protective board. The upper frame of side board and stop pad is welded in to all in one. The bottom board framework is trapezoid structure. The van cargo body is closed for all sides. The floor is metal-wood or metal structure. The tail is double doors. The two side walls can be deployed the side doors or shutters. The width lights are mounted in front and rear side top of the cargo body. There are lamps in the cargo body. The extinguisher is equipped in front side. Protective fender and marking lights are equipped on the sides and steps is designed at the rear. Dumping Mechanism Itis only used for dump truck, connecting rod combined type structure, single step piston oil cylinder. Power Take-off Only used for dumping truck. The parameter as follows: Type: Power take-off by reverse speed; Ratio: 1.361; Rated output torque: 294N.m/(1000r/min). towing seat JSK36DV towing seat with 50# towing pin. Tools Equipped with necessary tools for maintenance. 119o@ Diagram of Brake Line rey 1. Air compressor 13. Fast release valve 2. Unloading valve 14. Dual-way valve 3. Air dryer 15. Dual chamber brake valve 4. Wet air tank 16. Hand control valve 5. Four-way protective valve 17. Exhaust brake solenoid 6. Front air tank 18. Air horn solenoid 7. Rear air tank 19. exhaust brake valve 8. Control valve for trailer 20. Air horn 9, Disengaging switch 21. Front brake chamber 10. Disengaging switch 22. Dual hands air pressure gauge 11. Spring brake chamber 23. Fast release valve 12. Load sensing valve na ne I 120 l®. Front brake chamber Fast release valye Braking valve Combination air compressor Dryer Four-way protective valve Front axle air tank Rear axle air tank Subsidiary air tank 10. Hand control valve 11. The valve of trailer 12. Load sensing valve 13 Spring brake chamber 14. Differential valve 15. Combined pipe fitting L 2. 3s 4. 3: 6. fl 8. 9: Brake valve Brake valve Brake valve Brake valve p. Differential Valve q. Differential Valve A: Exhaust br. B: To connect clutch booster . Hand control valve C: To connect the gear box Hand control valve Hand control valve . Trailer valve Trailer valve Trailer valve Trailer valve Trailer valve |. Trailer valve Differential Valve Differential Valve 121@ Diagram of Electrical Wiring esas Electrical wiring color 122@ Diagram of Electrical Wiring aL We Wussanu a Electrical wiring color Color c/w R/BL R/BL wst | B/Y wss | R/Y ws9 | B/W Wo3 123 Note: 1.G = green; 2.W = white; BR = red 4.B = blue; S.BL = black; 6.BR = brown; 7.P = pink; 8.Y = yellow; 9.GR = grey