DFL1160 999系列 (KD5K) 使用手册 EN

Dongfeng DFL1160-999 Motor Chassis
User’s Manual
DONGFENG MOTOR CO., LTD.
August 2010
D530.KD5K.H1008
Foreword
Thanks for purchasing and using Dongfeng motor vehicles, and we wish they will bring you infinite
wealth.
It is our common objective to optimize your vehicle, which, however, to a certain extent, depends on
your familiarity with the vehicle and maintenance. You are appreciated to have a careful reading of this
manual and thus to get familiar with operation procedures therein before your use.
Models the manual applicable are: DFL1160-999
This manual is part of the vehicle, and thus should be delivered with the vehicle.
It should be aware that the illustrations and instructions in this manual are right when the manual is
published, while the structure and function of our products are always under development and
perfection. There exists possibility that the introduction in this manual cannot match the actual structure.
We’re sorry that we will not notify you of all the possible discrepancies. Parameters related to the
announcement are in accordance with the state-announced parameters.
Problems related to quality warranty and component purchase of our products, please contact
Dongfeng Commercial Vehicle Technical Service Center (Station) or customer service center of
Dongfeng Commercial Vehicle Co., Ltd. Sunshine service Hotline: 0719-8885555 or Free Call: 800-880-
5800.
DONGFENG MOTOR CO., LTD.
2010.08
D530.KD5K.H1008
Declaration
DONGFENG MOTOR CO., LTD. shall be relieved from the products’ reliability, safety or compatibility in
case of one of the followings:
1. The name plate and the certificate of the vehicle or chassis issued by our company do not match
the material object, or are altered.
2. Fail to observe the request in this manual to perform proper use and specified operation to the
vehicle.
3. No regular maintenance (including running-in maintenance and mileage maintenance) is executed

in according with this manual.
4. Fail to use the oil products, coolant, air filter elements, fuel filter elements and oil filter elements
designated by this manual.
5. The customer tries to repair the vehicle when it is multifunctional within the quality warrant period
instead of getting it repaired in the Technical Service Center (Station) of Dongfeng Commercial
Vehicle Company or Dongfeng Commercial Vehicle Company.
6. Malfunction caused by altering the original structure of the vehicle without authorization of our
company, such as refit, retrofitting, or changing the parts, namely, extending the room,
strengthening the frame, thickening leaf spring or layering or widening the tyres.
7. Malfunction caused by failing to use the genuine parts recognized by our company when repairing
the vehicle.
8. Continue to drive while not clearing the malfunction or substantial fault. Enlarging successive fault
and consequent related components breakage.
9. Performing unauthorized disposal without the duty division executed by involved parties such as
security transportation administrative authority and insurance company after the traffic accident
occurs.
10. The vehicle is operated overloaded or ultra limited.
11. Impacting, burning damage, scratching or chipping caused by external factor but not the internal
fault of the products.
12. Vehicle damage caused by irritable force of the natural environment, such as flood, lightening,
storm and hailstone.
13. Normal deterioration of the vehicle like noise, vibration, wearing and aging.
14. Delay loss caused by stopping or refusing the service station to perform regular inspection,
analysis and evaluation to the vehicle.
15. Vehicles that are no more in quality warrant period.
16. Other repairs not associated with material, design or manufacturing. Modification or refit of vehicles
without permission.
D530.KD5K.H1008
Signs in the manual are specified as follows:
Warning: the failure to observe the warning contents will result in serious personnel
injury or property loss.
Caution: the failure to observe the noted contents will result in personnel injury or the
damage of component assembly or complete vehicle.
All rights reserved.
D530.KD5K.H1008
Contents
Vehicle Identification.......................................... 1 Adding Fuel ................................................. 49
Location of the Model Nameplate ................. 1 Warning Triangle ......................................... 49
Location of VIN.............................................. 1 Diagnostic Fault Code ................................ 50
Location of the Engine Nameplate................ 1 Levers ......................................................... 51
Location of Fuel Injection Pump Nameplate . 2 Check of Drier ............................................. 52
Location of ECM Nameplate ......................... 2 Methods to Release Spring Brake .............. 53
Daily Inspection ............................................. 3 Rear Guard Rail .......................................... 53
Running-in of New Vehicle ............................ 4 Start and Drive .................................................. 54
Standard Operation ....................................... 5 Engine Start ................................................ 54
Structure and Operation .................................. 10 Clutch Operation ......................................... 56
Instruments and Control Mechanism .......... 10 Brake Operation.......................................... 57
Keys ............................................................ 11 Parking ........................................................ 57
Doors ........................................................... 11 Slope Driving Method ................................. 57
Seat ............................................................. 12 Maintenance and Adjustment ......................... 58
Passenger's Seat ........................................ 13 Checking and Adding Coolant .................... 58

Berth ............................................................ 13 Radiator Liquor Drainage ........................... 59
Safety Belt ................................................... 14 Maintenance of Air Filter ............................. 59
Instrument Board......................................... 15 Engine Lubricating Oil................................. 61
Indicator Lamps ........................................... 18 Oil Filter....................................................... 62
Rocker Switch ............................................. 23 Fuel Filter .................................................... 62
Operating Switch ......................................... 25 Draining of Oil Water Separator ................. 63
Cruise Operation ......................................... 28 Adjustment of Valve Clearance .................. 64
Remote Throttle and Remote PTO ............. 29 Inspection of Clutch Fluid Level.................. 64
Ventilations .................................................. 31 Adjustment of Clutch................................... 65
Air Conditioning System .............................. 33 Clutch Exhaust............................................ 65
Accessory System....................................... 36 Inspection of Final Drive Oil Level .............. 66
Comprehensive Alarm ................................. 42 Inspection and Change of Transmission Oil67
Multi-purpose Buzzer .................................. 42 Maintenance of Wheel Hub Bearing........... 67
Central Distribution Box .............................. 43 Maintenance and Adjustment of Brake....... 69
Adjustment of Steering Wheel..................... 45 Inspection of Brake Pedal Stroke ............... 71
Towing Hook ................................................ 46 Adjustment of Front Wheel Toe-in .............. 72
Front Faceshield ......................................... 46 Inspection and Change of Power Steering
Hydraulic Oil................................................ 73
Fire Extinguisher ......................................... 47
Inspection of Steering Wheel Free Rotation74
Cab Tilting ................................................... 48
Inspection and Maintenance of Battery ...... 74
Manual Cab Tilting Operation ..................... 48
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Fuse ............................................................ 75 Mass Parameters...................................... 100
Positioning of the Light................................ 76 Dimension Parameters ............................. 100
Method of Adjusting Light............................ 77 Performance Parameters ......................... 101
Auxiliary Power Starting .............................. 79 Assembly Structure ....................................... 102
Disassembly and Assembly of Spare Tyres 80 Engine ....................................................... 102
Tyre Inflation Device.................................... 80 Clutch ........................................................ 102
Change of Tyre ............................................ 81 Transmission............................................. 102
Recommended Tyre Use and Maintenance 82 Driving Shaft ............................................. 102
Interchanging of Wheels ............................. 83 Front Axle .................................................. 103
Inspection of Tyre Pressure and Tyre Tread83 Rear Axle .................................................. 103
Periodic Maintenance Schedule ..................... 84 Wheel and Tyre ......................................... 103
Inspection and Maintenance Term .............. 84 Suspension ............................................... 103
Periodic Renewal Part ................................ 89 Frame........................................................ 103
Grease Filling Mileage Schedule ................ 89 Steering System........................................ 103
Maintenance and Adjustment Data................. 91 Brake System ........................................... 103
Engine Section ............................................ 91 Electrical System ...................................... 104
Chassis Section .......................................... 92 Cab............................................................ 104
Tightening Torque........................................ 93 Heater and A/C ......................................... 104
Bulb ............................................................. 96 Carriage .................................................... 104
Capacity Data .............................................. 97 Driver's tool ............................................... 104
Oil and Grease ............................................ 97 Schematic Diagram of Brake ........................ 105
Technical Parameters .................................... 100 Electrical Schematic Diagram ...................... 105
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Vehicle Identification
Location of the Model Nameplate
Location of VIN
VIN means vehicle identification number, printed

on an evident location on the right side rail of the
frame.
Location of the Engine Nameplate
Engine nameplate provides the exclusive data of

engine. The engine production serial number and
control parts list (CPL) number provide the
information required for part order and
maintenance. The above information should be
subjected to the product technical document, and
no further notice will be made upon any
modification.
1. Engine nameplate
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Location of Fuel Injection Pump Nameplate
The nameplate of Bosch fuel pump is on the top of

fuel pump.
Location of ECM Nameplate
ECU is in the instrument board in the cab.
Electronic control module (ECM) nameplate

provides relevant information of ECM. This
nameplate is on ECM.
ECM nameplate provides the following

information:
ECM part number (PN);
ECM production serial number (SN);
ECM date code (DC);
Engine production serial number (ESN);
ECM code: indicating the software in ECM

Caution:
1. Supply your engine's ECM code
when you contact the maintenance
station of Dongfeng Engine
Company.
2. Do not wash electronic control
module ECM with water; otherwise it
will result in short circuit or poor
contact.
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Daily Inspection
Please check carefully the vehicle before driving.
1. Check the coolant level (see Page 69).
2. Check the lubricant level of the engine (see Page 72).
3. Check the engine oil pressure gauge, thermometer, warning indicator lamp and other meters for
normal operation.
4. Check the fuel filter (see Page 74)
5. Check the drainage of oil water separator (see Page 74).
6. Check the power steering oil level.
7. Check the fuel tank level (see Page 63).
8. Check the tyre pressure and tyre tread.
9. Drain water from the air vessel.
10. Check and clean the glass and rearview mirror.
11. Check the clutch hydraulic oil level.
12. Check the horn.
13. Check the light.
14. Take care to avoid scald when unscrewing the pressure valve cap, and tighten the cap after filling.
15. Ensure the cooling system is complete and effective (water tank cap etc.).
16. Check the fan belt and fan for damage.
17. Check the coolant in time if the temperature is too high or too low.
18. Replace the deicing fluid after overheating of engine. (The engine cannot run without thermostat)
19. Check the engine oil level and ensure it's in safe position; check for oil leak.
20. Ensure the lubrication system is complete (engine oil cap etc.).
21. Ensure the engine oil pressure is normal and check it in time if the pressure is too low.
22. Check the engine oil in time in the event of emulsification.
23. Check the steering wheel, gear lever and brake conditions.
24. Check the engine oil in time if the level rises, and check te steering booster pump oil seal for
damage.
25. Check the engine oil in time in the event of excessive consumption.
26. Check the exhaust filter element for clogging, icing up and check the mounting position through
visual observation.
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27. Check the clutch pedal free stroke.
28. Check the brake pedal free stroke.
29. Check the clips and hoses in the intake system for evident looseness, damage and leak.
30. Check whether the intercooler surface is clean through visual observation.
31. Check the exhaust pipes for deformation and leak.
32. Check the engine running for abnormal sound and excessive vibration.
33. Check whether engine throttle response is sensitive.
34. Check for evident fuel leak.
35. Check whether the connections are reliable and whether there are malfunctions.
Running-in of New Vehicle
Running-in mileage is 1,500~2,500km, the following should be noticed during the running-in period:
1. Loading is strictly prohibited in the first 250km of running-in. Never accelerate the speed of the
engine above 2,000 r/min.
2. The load should not exceed 75% of nominal load capacity during running-in period after 250km.
3. Drive the vehicle on the hard road with minor slope throughout the running-in period and do not
drive in mountainous districts.
4. Run with proper light load or idle load for a while to warm up after starting the engine.
5. To avoid damage of starter, the engine starter engagement time should not exceed 30s and the
interval between two successive starts should be 2min.
6. Prevent long time constant speed operation of the vehicle.
7. Properly use the transmission gears to prevent the engine to run overload.
8. Pay constant attention to the oil pressure and temperature of the engine.
9. Check frequently the lubricant level and coolant level of the engine.
10. For vehicles of which the cooling system adopts flexible seal protection, check whether the seal
clamp is loose. Re-tighten it if it gets loose.
11. Drive the vehicle moderately and prevent emergency braking.
12. Never cutoff abruptly after the engine has been running at high speed or with high load for a long
time. Keep the engine running in idle after driving, and cutoff after the engine is cooled.
Caution: Please perform running-in maintenance during the running-in period in local
technical service center (station) authorized by Commercial Vehicle Company of
Dongfeng Motor Group Co., Ltd. in accordance with the rules of Dongfeng Commercial
Vehicle Quality Assurance Manual.
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Standard Operation
In order to increase the service life, gain higher economic benefit, and guarantee the travel safety, the
following should be noticed when operation the vehicle:
1. Turn on the power switch.
2. Remove the battery at least after 30s of disconnecting the solenoid switch when to replace the
battery.
3. Confirm the transmission is in neutral position.
4. Start the engine according the technical specifications.
5. Do not increase the engine speed too fast if the engine temperature is low; otherwise it will
aggravate the wear of engine moving parts.
6. Do not wash ECM with water.
7. Disconnect the ECM wiring when to weld.
8. The vehicle cannot start until the brake system air pressure reaches or exceeds 535kPa.
9. The vehicle must start in 1st gear while under heavy load.
10. Avoid full throttle start and emergency braking. Full throttle start will result in clutch damage or
uneven tyre wear; while emergency braking will accelerate the wear of tyres and brake linings.
11. Avoid sharp turn at high speed.
12. Forbid overload operation of vehicle since it may shorten the service life of vehicle.
13. When loading through mechanical equipment, try to load from low position so as to avoid impact
and damaging the machine members.
14. Do not allow water to enter the oil tank when washing your vehicle.
15. Do not turn off the power switch during engine running; make sure to turn off the power switch
when the vehicle stops.
16. Check for objects that are easy to get upside-down before tilting the cab, and remove the objects if
there is any.
Warning:
According to the regulation of Article 48 in the Road Traffic Safety Law of the People's
Republic of China: “A motor vehicle that carries goods shall conform to the ratified load
capacity, and it is strictly prohibited to be overloaded”, the user should operate the
vehicle in strict observation with the Instruction Manual, loading exceeds the nominal
capacity specified in the manual is strictly prohibited. Overload may result in
malfunction and damage on the vehicle and even may cause personal injury.
17. Protect the electronic control unit of the vehicle as following before perform electrical welding on
the vehicle:
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For vehicle equipped with electromagnetic main power switch
Output (+) Output (+) Control

Control terminal
Electromagnet terminal
ic main power
Ground
switch Ground
Input (+) Input (+)
Vehicle
Vehicle frame
frame
Initial state State before

welding
Operation procedures:
a. Disconnect the positive lead of electromagnetic main power switch output terminal.
b. Short the input terminal of electromagnetic main power switch and positive lead of output terminal.
c. Disconnect te positive and negative cables of battery.
d. Connect the positive and negative cables and touch them to the frame.
Warning:
1. Prevent power short circuit while disconnecting and connecting the power cord.
2. Restore all wirings after electrical welding.
3. Failing to perform electrical welding in this way may result in irremediable defect of
vehicle electronic devices.
Warning: Failing to observe the warning contents will result in serious personnel injury
or property loss.
1. According to the regulation of Article 48 in the Road Traffic Safety Law of the People's Republic of
China: “A motor vehicle that carries goods shall conform to the ratified load capacity, and it is
strictly prohibited to be overloaded”, the user should operate the vehicle in strict observation with
the Instruction Manual, loading exceeds the nominal capacity specified in the manual is strictly
prohibited. Overload may result in malfunction and damage on the vehicle and even may cause
personal injury.
2. Make sure to observe the technical specifications to protect vehicle electronic equipment during
welding; otherwise it will result in irremediable defect of vehicle electronic devices. (see Page 5)
3. The safety belt can be used by one person only. Adult and kid are prohibited to share one belt. The
entire belt must be replace in the event of retractor binding or any component failure and damage.
It shall be ensured that the safety belt is not intertwined, contacted with hard edges and free from
chemical pollution. Make sure to adjust the belt length according to the body; otherwise it will cause
hazard.
4. The brake system air pressure must be greater than 650kPa upon start.
5. The release of spring brake is limited to emergency only. Restore the normal function of parking
brake after troubleshooting. Operating the vehicle without parking brake is dangerous, and is likely
to cause injury.
6. Never leave the cigar lighter connected too long. In case it cannot eject automatically for a long
time, do pull it out manually.
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7. Adjusting the position of the steering wheel is strictly prohibited during driving.
8. Park the vehicle on the flat ground before tilting the cab. Check for sufficient space when to tilt the
cab inside. Check whether the manual valve control lever is in braking position, transmission
control lever is in neutral position and block the tyres with triangular fillet. Arrange the spreaded
objects inside the cab and those which are easy to fall during cab tilting. The cab must be tilted in
position; tilt the center of gravity over the support point to avoid the cab to slide accidentally. After
tilting the cab in position, make the tilting stop lever straight and insert the safety pin in the hole
near the titling retainer.
9. Do not touch the shift control lever while the engine is running during cab tilting; do not lower the
cab with engine running.
10. Do not replace the fusible link (fuse) with plain conductor fuses of other specifications.
11. Use the oils and greases according to this manual strictly; otherwise it may cause vehicle
malfunction, damage and even personal injury.
Caution: Failing to observe the noted contents will result in personnel injury or the
damage of component assembly or complete vehicle.
1. Observe the vehicle operation technical specifications strictly (for start and drive, see Page 5).
2. Check and ensure all doors are closed before starting the vehicle.
3. Lock the door with key only when you are outside the vehicle; do not pull the lock knob forward
while pressing the door outward opening button to lock the door.
4. Make sure to switch on the drier's heater when the ambient temperature is below 8 ℃.
5. Do not turn off the power switch with engine running. Strictly prohibit turn the key to START position
when the engine is running to avoid damaging it.
6. Do not use the washer without washer fluid.
7. When the refrigeration compressor of A/C should be restarted, wait for 3 ~ 5min; otherwise it will
impact the service life of refrigeration compressor.
8. During high and low gear shifting, make sure to operate the clutch by two feet. Ensure to release
the clutch completely upon gear shifting. The gear lever should be engaged in position. When
shifting from low gear zone to high gear zone (or conversely), the driver should consciously wait a
moment for the shift of a air circuit between high gear and low gear. Do not shift between high and
low gears when driving down the slope. Start the vehicle in 1st gear according to the road
conditions.
9. For the sake of safety, make sure to close the ashtray before leaving the vehicle.
10. Avoid "pumping" the brake pedal; otherwise it will bleed the air inside the air vessel and cause
vehicle out of control.
11. Do not apply emergency brake except for emergency. In particular in raining days when the road
surface is slippery, using emergency brake may result in lateral sliding or other hazardous
conditions.
12. After vehicle washing or passing through deep water pit, water may enter the brake drum and
reduce the brake efficiency. Depress the brake for several times while running at a low speed to
evaporate the water and guarantee the normal operation of brake.
D530.KD5K.H1008 7
13. Before adding coolant, check whether there is leak in engine and radiaor. Repair them if there is
any. It's recommended to use the long acting freezing and corrosion prevention coolant made by
Dongfeng Motor Co., Ltd. Do not use tap water or hard water from well and river.
14. Generally do not unscrew pressure valve cap. Take care to avoid scald when unscrewing the filler
cap.
15. Check the engine oil level when the vehicle is stopped. Make sure to drain the lubricating oil off
after the engine completely stops. Note the hot oil to avoid scald during oil draining.
16. When mounting the air filter, make sure to mount the filter element and end cap properly; otherwise
it will suck dust and greatly shorten the service life of engine. Never clean the filter element with
gasoline or water. Check the sealing rings when performing installation. Tighten the filter element
and end closure nut, and make sure the sealing ring of the end closure is properly installed. Do not
remove the air filter with vehicle running.
17. Do not fasten the fuel prefilter and fuel filter and with filter spanner when mounting them; otherwise
it will cause threads deformation and filter damage. When mounting the new filter, note whether the
model conforms to that required by this vehicle model. Fill the oil filter with oil before mounting it.
18. Running the engine without turning on the coolant filter inlet switch will result in engine damage.
19. Do not exhaust if the engine is very hot. The duration every time the engine is started should be no
more than 30 s, and interval between starting should be no less than 2 min.
20. Adjust the air valve clearance with engine in cold state.
21. Keep the brake fluid clean and seal the fluid. Do not use mineral oil as brake fluid. Do not use
brake fluids of different quality or different grades and models.
22. Do not allow the dust or dirt to enter the final drive when filling oil to the intermediate/rear axle.
Keep the oil level at proper position. Both too low and too high oil level will impact the service.
Always keep the breather plug clear.
23. Too low transmission oil level may result in bearing and gear burning, and too high level may result
in overheating and oil leak. Always keep the breather plug clear.
24. For manual adjusting arm, check the brake clearance frequently and adjust it in time if the braking
is weak. When adjusting the brake, note do not change the push rod stroke through tightening the
connecting yoke of brake air chamber push rod. To adjust the rear brake, make sure to park the
vehicle on the level place and ensure the air vessel pressure is above 700kPa. Block the wheels
with triangular fillet at the front and back and release the parking brake before adjusting the rear
brake clearance.
25. For self-adjusting arm, do not adjust the brake clearance manually except for particular cases;
check the wear conditions of wearing plate periodically to prevent brake failure due to excessive
wear; do not change the push rod stroke through turning the connecting yoke of brake air chamber
push rod during manual regulation of brake clearance; during manual regulation of rear brake,
make sure to park the vehicle on the flat place and ensure the air vessel pressure is above 700kPa.
Fix the wheels with doubling fillet from front and hind, the rear brake can only be adjusted after
releasing the parking brake. In the case of self-adjusting arm abnormal conditions, stop the vehicle
immediately, check the working conditionss of self-adjusting arm and other brake system parts and
adopt proper measures to eliminate the faults in time.
26. Do not adjust the brake air circuit pressure without permission so as to avoid parts damage.
27. Do not fill power steering hydraulic oil with engine running.
8 D530.KD5K.H1008
28. Stall the engine before checking the power steering hydraulic oil level.
29. Do not allow the steering wheel to stay in limit position over 15s. Turn the steering wheel back a
little to prevent steering booster pump damage.
30. When performing vehicle maintenance in accordance with the specified maintenance item, the user
should shorten the maintenance interval mileage according to the actual operation condition, to
ensure more reasonable maintenance and better performance of your vehicle, however, the user
should never extend the maintenance interval mileage.
D530.KD5K.H1008 9
Structure and Operation

Instruments and Control Mechanism
1. Driver side intake (see Page 42) 9. Brake pedal

2. Instrument board and control panel 10. Combination switch’s right handle (including
3. Passenger side intake exhaust brake, windshield wiper and washer
4. Radio & Cassette Player switch) (see Page 32)
5. Heater A/C Controller 11. Combination switch’s left handle (including
6. Cigarette lighter (see Page 44) horn, position lamp, high beam, low beam
7. Transmission control lever (see Page 62) and dimming switch) (see Page 31)
8. Throttle pedal 12. Clutch pedal
10 D530.KD5K.H1008
Keys
Keys are to control starting switch of the vehicle

and to lock and open the door.
Doors
From Outside the Vehicle
Insert the key in the lockhole and turn the key

counterclockwise in the case of driver;s side door
or clockwise in the case of passenger's side door,
then the door will be unlocked; contrarily, the door
will be locked; after door unlocking, turn the door
handle upward, and the door will open.
1. Locking position 3. Key inserting
2. Unlocking position position
4. Door outward
opening button
From Inside the Vehicle
Turn the lock knob forward, and the door will be

locked. Contrarily, the door will be unlocked; turn
the inside door handle, and the door will open.
Caution:
1. It's very dangerous to drive with
door half-closed. Check whether the
doors are closed when the buzzer
releases warning. 1. Inside door 3. Inside door
2. Lock the door with key only opening handle locking position
when you are outside the vehicle; 2. Inside door
do not pull the lock knob forward unlocking position
while pressing the door handle to
lock the door.
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Seat
Driver's Seat (commone type-mechanical

damping type)
1. Rotate this knob to adjust the seat to allow

better riding according to the driver's weight.
2. Pull the backrest angle regulating lever to

adjust the backrest angle and lock the
backrest angle when releasing the lever.
3. Pull the backrest angle adjuster operating

handle to adjust the backrest angle and lock
the backrest angle when release the lever.
4. Press the adjusting knob under the head

restraint by one hand and move the head
restraint vertically by another hand to adjust
1. Body weight 3. Backrest angle
the height; release the adjusting knob, and
adjusting knob adjuster
the head restraint will be locked.
2. Front and back 4. Head restraint
regulating lever
Driver's Seat (advanced configuration- airbag damping type)
After riding, cushion of the airbag damping type

seat will rise slowly and adjust to appropriate state
automatically according to the driver's body
weight.
1. Pull the seat front and back regulating lever to

adjust the seat to the proper position and lock
the seat when releasing the lever.
2. Pull the backrest angle adjuster to adjust the

backrest angle and lock the backrest angle
when releasing the lever.
3. Press the adjusting knob under the head

restraint by one hand and move the head
restraint vertically by another hand to adjust 1. Front and back 3. Head restraint
the height; release the adjusting knob, and regulating lever
the head restraint will be locked. 2. Backrest angle
adjuster
12 D530.KD5K.H1008
Passenger's Seat
Pull/press backrest
1. When to use the backrest, pull it upward to
the rearmost position and then pull it
downward to the lowest position.
2. When to draw the backrest, pull the backrest

upward for a short distance by both hands
along the backrest inclination and then tilt it
forward to set the backrest horizontal.
3. Hold the seat armrest to keep your body

stable in the event of excessive vehicle body
vibration.
1. Seat armrest
Berth
1. Have your head at the berth side with head

restraint when resting in the berth;
2. Turn the berth upward to reveal the glove

boxs at left and right sides under the berth,
which can be used to accept tools and
personal effects;
3. To prevent objects shaking during vehicle

running, fix the objects with the tape in the
glove box.
1. Berth 2. Left and right glove

boxs of berth
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Central Control Lock
Please refer to the specific configurations of purchased products.
From Inside the Vehicle
When both driver and passengers are in the vehicle, switch the lock knob on driver side to locking
position, and the door on passenger side will be locked as well. Switching lock knob on passenger side
to locking position can only lock the door on passenger side, leaving the door on driver side unlocked.
From Outside the Vehicle
When unlocking the door on driver side with the key, the door on passenger side will be unlocked as
well. Press the outer opening lock to open the doors on driver side and on passenger side respectively.
When unlocking the door on driver side with the key, the door on driver side can be opened by pressing
the outer opening button, leaving the door on driver side unopened. Lock the door on driver side with
the key, and the door on passenger side will be locked as well. Locking the door on passenger side with
the key can only lock the door on passenger side, leaving the door on driver side unlocked.
Safety Belt
Driver’s Seat Belt
1. Pull the belt out slowly, put it between the

shoulder and the base of neck, insert the tag
in the buckle at a proper position of the chest,
check whether it is buckled up after a click
and adjust the belt until feeling comfortable.
2. Unfasten safety belt: press the button on the

buckle to release the tag and put the belt
back slowly.
1. Buckle 2. Tag
Center Seat Safety Belt
Adjust the safety belt length according to the body

conditions until you feel good. Insert the tab in the
lock catch until a click is heard then the belt is fully
locked. The center passenger should fasten the
safety belt around the crotch as far as possible
other than the waist.
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Instrument Board
Please refer to the specific configurations of purchased products.
1. Water thermometer (see Page 18) 8. Intermediate/rear axle manometer (see Page
2. Fuel gauge (see Page 18) 24)
3. Trailer turn indicator lamp (disconnected) 9. Indicator lamp and warning lamp
4. Turn indicator lamp (see Page 19) 10. Mileage display (see Page 26)
5. Speedometer (see Page 19) 11. Backlight adjusting knob (see Page 26)
6. Engine speed recorder (see Page 18) 12. Mileage subtotal reset (see Page 26)
7. Front axle manometer (see Page 19) 13. Engine shutdown and engine service warning
lamp
D530.KD5K.H1008 15
Engine Speed Recorder
The pointer of the engine speed recorder indicates

the engine’s revolution number per minute. The
economic Cummins engine speed is 1,200 ~
1,700r/min and the warning speed is 2,200r/min.
Speedometer
Speedometer indicates the running speed of

vehicle (in km/h).
Barometer
Barometer indicates air pressure in air vessel.

Front axle barometer (with the sign of FR) detects
pressure of front axle air vessel, and
intermediate/rear axle barometer (with the sign of
RR) detects pressure of intermediate/rear axle air
vessel.
Red area indicates air pressure range within which

the vehicle cannot be started. The vehicle cannot
start until the brake system air pressure exceeds
650kPa.
Warning: The brake system air

pressure must be greater than 1: Front axle 2: Rear axle
535kPa upon start. barometer barometer
16 D530.KD5K.H1008
Water Thermometer
This meter indicates the temperature of engine

coolant. Switch the key to ON and the meter will
work. C on the dial means low temperature and H
means high temperature. Ideal temperature is
when the pointer is within the range of middle
scribed lines.
Caution:
When coolant temperature is too H:120 ℃ 2:80 ℃
high, the high water temperature 1:100 ℃ C:40 ℃
indictor lamp turns on, and then the
buzzer on instrument board sends an
alarm. When coolant temperature is
too high and the vehicle continues
driving, engine will be damaged due
to overheat.
Fuel Gauge
Fuel gauge indicates the fuel level in fuel tank.

Switch the key to ON and the meter will work. On
the dial F means fuel tank is full, and E means the
fuel is exhausted. When the pointer is close to E,
refill the tank with clean fuel.
Turn Indicator Lamp
This lamp is used to indicate the working

condtions of turn lamp, and it will change the
flicker frequency to warn if the turn lamp bulb is
damaged.
D530.KD5K.H1008 17
Indicator Lamps
1. Low beam indicator lamp 19. Transmission low gear indicator lamp
2. Inter-axle differential lock indicator lamp 20. ASR system failure indicator lamp
(disconnected) (disconnected)
3. Parking brake indicator lamp 21. Air filter clog warning lamp
4. Filament detection warning lamp 22. Main vehicle ABS system failure indicator
5. No charging indicator lamp lamp (optional)
6. Low oil pressure warning lamp 23. Trailer ABS system failure indicator lamp
7. High beam indicator lamp (disconnected)
8. Exhaust brake indicator lamp 24. Low water indicator lamp
9. Rear fog lamp indicator lamp 25. PTO indicator lamp
10. Air drier heating Indicator lamp 26. Cruise indicator lamp (disconnected)
11. Fuel preheating indicator lamp (disconnected) 27. Air bag indicator lamp (disconnected)
12. Safety belt indicator lamp 28. Air suspension indicator lamp (disconnected)
13. Door opening warning lamp 29. Power takeoff indicator lamp (for dump truck
14. Front fog lamp indicator lamp chassis only)
15. Inter-wheel differential lock indicator lamp 30. Air defense indication
(disconnected)
16. ECAS warning lamp/ECAS failure warning
lamp (disconnected)
17. Transmission high gear indicator lamp
18. Retarder indicator lamp (disconnected)
18 D530.KD5K.H1008
Air Processing Unit Heating Indicator Lamp
When the air processing unit heating switch is in

on position, this indicator lamp will turn on to
indicate the heating circuit of unit is connected.
Rear Fog Lamp Indicator Lamp
When the rear fog lamp switch is turned on, this

indicator lamp will illuminate.
No Charging Indicator Lamp
This indicator lamp turns on when key switch is in

ON position. When the engine starts and charges
the battery, the lamp turns off. This lamp will turn
on if the charge stops as the charging system fails
during vehicle driving.
Caution:
It is prohibited to drive the vehicle
for a long time with the indicator
lamp lighting.
Filament Detection Warning Lamp
This indicator lamp turns on (except for trailer)

when any filament of rear fog lamp, tail lamp and
brake lamp is at failure. This function gives the
driver a hint of the working condition of tail lamp.
Safety Belt Indicator Lamp
When the driver does not fasten the safety belt,

the indicator lamp turns on to suggest him/her to
buckle up.
D530.KD5K.H1008 19
Warning Indicator Lamp
When hazard warning lamp switch is turned on, all

the turn lamps will illuminate and twinkle to remind
other vehicles.
Low Water Indicator Lamp
When the coolant level is below the specified limit

level, this indicator lamp will illuminate, and the
buzzer will sound at the same time. When the
engine stops and the key switch is turned off, the
buzzer will stop warning.
Caution:
When continuing driving with
insufficient coolant, engine will be
damaged due to overheat.
High Beam Indicator Lamp
This lamp will turn on when the head lamp

employs high beam; it will turn on as well when
overtake lamp is on.
Low Air Pressure Indicator Lamp
When the pressure of air vessel is below the

specified limit, this indicator lamp will turn on. At
this point, if the manual valve control lever is in
brake release position, the buzzer will send out
sound warning. When the lever is turned to
braking position or the air pressure meets the
requirement, the buzzer will stop warning.
Low Oil Pressure Indicator Lamp
The lamp turns on when turning key switch to ON

position, and goes on after the engine is started.
The lamp turns on to alarm too low oil pressure in
the course of engine running.
Warning:
Do not keep driving when this
indicator lamp turns on.
20 D530.KD5K.H1008
High Water Temperature Indicator Lamp
This indicator lamp will turn on when the coolant

temperature is too high.
Parking Brake Indicator Lamp
When the manual valve control handle is at

locking position, the lamp turns on to remind the
driver that the vehicle is in brake mode; After the
parking brake is released, indicator lamp turns off.
When starting the vehicle, it is necessary to check
if the indicator lamp turns off and the spring
parking brake is released.
Wait Indicator Lamp
With engine warming up or other preparation in

process, if this lamp turns on, it means you should
start the vehicle after this lamp turns off.
Exhaust Brake Indicator Lamp
This lamp will turn on when the electrically

controlled engine exhaust brake functions.
Low Beam Indicator Lamp
When combination switch’s right handle is at low

beam, the indicator lamp switches on.
D530.KD5K.H1008 21
Instrument Buzzer Alarm
High water temperature warning, low water level warning, low air pressure warning. When the buzzer is
warning, the corresponding warning lamp on the instrument will turn on.
Mileage Display
1. Mileage subtotal
2. Mileage total
Mileage subtotal includes two: subtotal and

subtotal b
In subtotal a state, pressing mileage subtotal reset

button for a long time will reset subtotal a;
In subtotal b state, pressing mileage subtotal reset 1. Mileage subtotal 3. Mileage subtotal
button for a long time will reset subtotal b; 2. Mileage total reset
Short pressing mileage subtotal reset button will
switch subtotal a and subtotal b.
Failure Display
The failure display will show the failure code Failure code
Number of
automatically in the case of a failure. Diagnosis current failures Current failure SN
through diagnostic switch is not required. When
there are more than one failure:
1. Turn the left press key right to increase the current failure serial number to view the following
failures;
2. Turn the left press key left to reduce the current failure serial number to view the failures thereof.
When the failure total is 1, it indicates there is only one failure.
For failures occur at the same time, the failure serial number will sort from small to large according to
SPN. For the subsequent failures, rank them backwards in turn. For the subsequent failures occur at
the same time, sort them from small to large according to SPN.
Backligt Adjusting Knob
Turn the knob right to adjust the luminance of

instrument backlight
Turn the knob left to increase the luminance of

Turn the knob right to reduce the luminance of

22 D530.KD5K.H1008
Rocker Switch
Front Fog Lamp Switch
With small lamp switched on, press this switch,

and the front fog lamp will turn on.
Room Lamp Switch (for advanced configuration cab)
Press this switch, and the fluorescent lamp or

dome lamp on the cab roof will turn on.
Rear Fog Lamp Switch
When high beam, low beam or front fog lamp is

switched on, press this switch, and the rear fog
lamp will turn on.
Hazard Warning Lamp Switch
When hazard warning lamp switch is on, front,

rear, left and right turn lamps all turn on and blink
to remind and warn other vehicles.
Air Drier Switch
When this switch is pressed to connection

position, the drier heating indicator lamp will turn
on.
Caution:
Make sure to switch on the drier's
heater when the ambient temperature
is below 8℃.
Power Switch
D530.KD5K.H1008 23
This switch control the on and off of entire vehicle

power. Open the lock catch first and then shut off
the entire vehicle power before turn the power
switch off. Disconnect the power to protect other
electrical equipment during maintenance and
service of entire vehicle circuit system.
Caution:
Do not turn off the power switch with 1. Unlocking direction
engine running.
ABS Diagnosis Switch
When main vehicle ABS system failure indicator

lamp is on for a long time, it means ABS system is
at fault. Press ABS diagnosis switch for 1~3s
(when performing diagnosis, the vehicle must be
static), ABS diagnosis indicator lamp will produce
a series of blinks. Ascertain flash codes according
to the number of blinks, thereby diagnose
corresponding failure.
24 D530.KD5K.H1008
Operating Switch
1. Horn and lamp light combination switch 2. Exhaust brake, windshield wiper and washer
switch
Horn Switch
Press this button to sound the horn.
D530.KD5K.H1008 25
Combination Switch's Left Handle
This switch is the combination of front position

lamp, outline lamp, marker lamp, rear position
lamp, rear outline lamp, side marker lamp,
headlamp, gauge lamp, license plate lamp,
overtake lamp, dimmer and turn lamp (and cruise
switch of moderate or above model).
Lamplight Switch 1. Lamplight slip ring 4. Headlamp mark

2. Lamplight off 5. Lamplight mark
Turn the lamplight ring of the combination switch’s mark
control lever to switch on the following lamps: 3. Small lamp mark
Small lamp: when lamplight mark is aligned with

small lamp mark, front position lamp, rear position
lamp, outline lamp, marker lamp, license plate
lamp, side marker lamp and gauge switch’s
spotlight turn on.
Low beam: when lamplight mark is aligned with

headlamp mark, and switch lever is in low beam
position, low beam turns on.
High beam: when lamplight mark is aligned with

headlamp mark, and switch lever is in high beam
position, high beam turns on.
When low beam or high beam is on, small lamp

turns on as well.
Dimmer Switch and Overtake Lamp Switch
Dimmer switch must be used in the case of

opposite direction driving at night. Turn headlamp
on, and push combination switch’s control lever up
and down to realize the alternation between low
beam and high beam. Push the lever downward
from low beam position, and high beam of the
headlamp will be on continuously. When driving
normally, lift the lever to the highest point
regardless the service conditions of other
lamplight, overtake (high beam) will turn on. When
releasing the hand, the lever will reset 1. Dimming position 3. High beam
automatically and high beam will go off. 2. Low beam position
position
26 D530.KD5K.H1008
Combination Switch's Right Handle
Press top button on control lever, and washing

liquid will splash on the glass. When released, the
button will reset automatically.
Turn the slip ring to perform wiping function:
1. When wiper mark is aligned with INT, wiper

motor will work at intermittent speed. Time for
the wiper to remain static is 4~6s. 1. Wiper mark 2. Slip ring
2. Wiper motor stops when wiper mark is
aligned with OFF.
3. Wiper motor works at low speed gear when wiper mark is aligned with LO.
4. Wiper motor works at high speed gear when wiper mark is aligned with HI.
Caution:
1. Use wiper together with washer to avoid glass scratch;
2. It is prohibited to use washer without washing liquid.
Exhaust Brake Switch
1. Push switch control lever forward to on

position, the exhaust brake lamp will be on,
and when the accelerator and clutch pedal
are released, the exhaust brake will start to
work. Depress the accelerator or clutch pedal,
and exhaust brake will be released
automatically. When depressing either of the
accelerator or clutch pedal, the exhaust brake
will continue to work.
2. Pull switch control lever back to off position,

and exhaust brake will stop working and
exhaust brake indicator lamp will go off. 1. Switch on 2. Switch off
Caution:
When driving downhill, please use
exhaust brake.
D530.KD5K.H1008 27
Cruise Operation
Cruise Switch
Cruise Setting (during vehicle driving)
1. Setting vehicle speed
The cruise system allows you to maintain the

vehicle speed at 48km/h without depressing the
accelerator pedal. When the speed is over
48km/h, turn the cruise slip ring to ON position,
and turn the knob to S- position to set current
speed. Meanwhile release the accelerator, the
speed will be kept at the current level, and 1. Knob 2. Cruise slip ring
instrument cruise indicator lamp will turn on.
2. Change speed (not through depressing

accelerator pedal)
Turn the knob, keep it at R+ position and the

vehicle speed will increase continuously.
Turn the knob, keep it at S- position and the

vehicle speed will reduce continuously.
3. Exit cruise
The following ways can be used to exit cruise:
• Depress the brake pedal.
• Use the exhaust brake.
• Turn cruise slip ring to OFF position.
• When the vehicle speed is under 45km/h.
• Depress the clutch pedal to exit cruise, and release it to resume cruise.
Caution:
1. S- presents setting speed, and reducing speed; and R+ means resuming speed
and increase speed.
2. The speed will increase if accelerator pedal is depressed down at anytime, and
will resume its originally set speed after turning the knob to R+ position and then
releasing it.
3. If cruise system comes into failure, the system function will be canceled
automatically, and indicator lamp on instrument board will turn off.
28 D530.KD5K.H1008
Warning: Cruise control system cannot be used under the following circumstances to
avoid accidents caused by vehicle out of control.
1. When the vehicle can not run at a constant speed.
2. When the vehicle runs in adverse traffic environment.
3. When the vehicle runs under frequent speed change.
4. When the vehicle runs in windy weathers.
5. When the vehicle runs on curving roads or in mountainous areas.
6. When the vehicle is running on slippery road surface (rain, snow, ice surface, etc.).
Remote Throttle and Remote PTO
As Cummins Euro III engines have no throttle

cable, the remote throttle or PTO function will be
used during refit in the following way:
1. Using PTO switch function in the cab directly
(1) Engine PTO can function only when the PTO

switch is closed. In this case, the engine will
run at the rated speed set in the electronic
control module automatically, and will not 1. Knob 2. Cruise slip ring
change along with load.
(2) The corresponding PTO switch and R+/S-

switch in the cab are integrated in the
combination switch, diplex with cruise switch.
The center gear is for stop. The user should not operate the switch more than 0.5s. When R+/S- switch
is closed, the engine will run at the set rated speed. The user can use relay contact to replace PTO
switch and R+/S- switch as well, however, the time of closing contact should not exceed 0.5s. Where
R+/S- switch is pressed over 0.5s, the engine speed will keep increasing / decreasing. It's generally
used for idle adjustment.
2. Using preserved refit interface
The user can acquire the required signal at the preserved refit interfaces of chassis PTO, remote PTO
and remote throttle during refit to adapt the refit requirements. The preserved refit interfaces are located
in the frame harness, in the vicinity of battery. The wiring principle (Figure R-530-25) and interface form
(Figure R-530-26) are shown as below:
D530.KD5K.H1008 29
Remote throttle position

Water level sensor
Stop switch
Switch
Electronic throttle
CC/PTO switch
Remote throttle
Exhaust brake
Clutch switch
Remote PTO
switch
switch
switch
Switch
solenoid valve
Electronic fan
Main power
Exhaust brake solenoid valve
switch
Preheating
Electronic fan speed

relay
sensor
Where, 00 - 45A is for S-, 00 - 47A is for R+ and 00 - 28A is for PTO switch signal port. 04 - 83A is for
switch common port and the wiring is in parallel with combination switch PTO signal switch. 05 - 56 is
for remote throttle switch throttle switch port, 14 - 84 is for 5V power, 14 - 86 is for remote throttle return
wire, 14 - 48 is for remote throttle signal port. The remote throttle refit is as following:
(1) The remote throttle switch can switch on or off the remote throttle function.
(2) The function of remote throttle controlling the engine speed is the same as that of main throttle.
30 D530.KD5K.H1008
(3) The main throttle will be disabled when remote throttle functions.
(4) For the detailed parameters of remote throttle, refer to Cummins technical document AEB1567.
The recommended remote throttle assembly is 3759010 - T2500 (the assembly part number).
0555 is for remote PTO terminal. The remote PTO allows five remote PTO speed settings. When
PTO/CC switch closes, the remote PTO is closed once quickly. Each close operating time is less than
0.5s.
To facilitate power use in the cab for refit, a power interface for refit is preserved at the passenger's side,
fuse capacity of which is 15A.
Key Switch
1. LOCK (locking gear): keys can only be inserted and pulled out at LOCK position.
2. ACC (accessory gear): turn the key clockwise to ACC gear to power on related accessories.
3. ON (ignition gear): turn the key clock wise to ON gear to enter into ignition state, and the
instrument will start working.
4. START (start gear): turn the key clockwise to START position to start the engine. When loosening
your hand, the key will spring back to ON position.
Caution:
Strictly prohibit turning the key to START position when the engine is running to avoid
damaging it.
Do not start for a long time or frequently; otherwise battery eletricity loss or starter
damage will be caused.
1. The time to start the engine each time should not exceed 30s and the interval
between two successive starts should be 2min at least.
2. To assure safety, make sure to depress the clutch pedal when starting the engine.
Ventilations
Door Glass Regulator Switch
Turn the lever clockwise, the door glass will rise;

contrarily, the glass will lower.
D530.KD5K.H1008 31
Power Glass Regulator Switch (for advanced configuration)

Driver’s side
Locking switch: press this switch and the

passenger side switch on left and right door will be
locked.
Driver side switch: this switch is used to control

the power glass regulator at driver side. Both
switch rise and low include two gears, which can
control the power glass regulator in inching mode
or automatic mode.
Passenger side switch: this switch is used to

control the power glass regulator on the right door.
Warning: 1. Locking switch 3. Passenger side
1. Where the window glass is 2. Driver side switch switch
contacted during operation, make
sure to move the window backward.
2. When operating the passenger
side power glass regulator switch,
the driver must ensure there is no
obstacle preventing the correct
close of window.
3. The driver must ensure the
passenger will use the power glass
regulator switch correctly.
4. Do not allow head or hands to
reach out of the window during
power window rising.
Passenger Side
Passenger side switch: this switch controls the

elevation and descending of power glass regulator
on right door.
1. Passenger side switch
32 D530.KD5K.H1008
Air Conditioning System
Heater A/C Controller
1. Mode control knob 3. Temperature control knob

2. A/C button 4. Fan and inner and outer circulation knob
Mode Control Knob
1. Face blowing gear: blow face
2. Face and feet blowing gear: blow face and

feet at the same time
3. Feet blowing gear: blow feet
4. Feet blow, defrosting and defogging gear:

blow feet meanwhile defrost and defog the
glass
5. Defrosting and defogging gear: defrost and

defog the glass
Fan and Inner and Outer Circulation Control Knob
Outer circulation gear: fan shut down, A/C heater

system in natural ventilation state (introducing
ambient fresh air).
Left side 4 gears: to regulate the fan speed,

namely, to regulate the fan blast strength in 4
gears. The larger the digit, the higher the speed.
In addition, the A/C heater system is in natural
ventilation state (introducing ambient fresh air).
Inner circulation gear: fan shut down, A/C heater

system in indoor air circulation state.
Right side 4 gears: to regulate the fan speed,

namely, to regulate the fan blast strength in 4
gears. The larger the digit, the higher the speed.
In addition, the A/C heater system is in indoor air
circulation state.
D530.KD5K.H1008 33
A/C Button (A/C switch)
Connected (lamp on): cooling (compressor works)
Disconnected (lamp off): not cooling
Temperature Control Knob
Left half area (blue area): cooling area,
Right half area (red area): heating area
Heating Method
When using heating function, please follow these steps:
1. Adjust temperature control knob to heating area.
2. Adjust the fan and inner and outer circulation control button to any gear except for Outer circulation
gear and Inner circulation gear.
To increase heating up speed, the following measures can be adopted:
1. Turn temperature control knob to the extreme right (the maximal heating position).
2. Turn the fan and inner and outer circulation control knob to higher speed gear right to Inner
circulation gear.
Cooling Method
When using cooling function, please follow these steps:
1. Adjust temperature control knob to cooling area.
2. Adjust the fan and inner and outer circulation control button to any gear except for Outer circulation
gear and Inner circulation gear.
3. Press A/C knob (turn on the indicator lamp).
To increase temperature reduction speed, the following measures can be adopted:
1. Turn temperature control knob to the extreme left (the maximal cooling position).
2. Turn the fan and inner and outer circulation control knob to higher speed gear right to Inner
circulation gear.
3. Press inner and outer circulation button (turn on the indicator lamp).
34 D530.KD5K.H1008
Caution:
1. Please start the fan first when using cooling function and then press A/C switch,
otherwise cooling function cannot be started (indicator lamp of A/C switch does not turn on).
2. When turning off the A/C, please first press A/C switch (turn off indicator lamp of
the A/C switch), and wait 2~3min before turning off the fan. If the fan is turned off first,
A/C switch will get disconnected at the same time.
3. When A/C compressor needs to be restarted after closing, please wait for 3~5min.
Otherwise the service life of compressor will be affected.
Natural Ventilation Method
When using natural ventilation function, please follow these steps:
1. Adjust temperature control knob to cooling area.
2. Adjust the fan and inner and outer circulation control knob to outer circulation gear.
Defrosting and Defogging Windshield
Adjust temperature control knob to heating area, mode control knob to defrosting and defogging gear,
and press the fan and inner and outer circulation button to highest speed position of inner circulation, to
perform glass defrosting.
Adjust temperature control knob to cooling area, mode control knob to defrosting and defogging gear,
and press the fan and inner and outer circulation button to highest speed position of inner circulation, to
perform glass defogging.
Precautions for A/C System Use
1. Warming device employs engine coolant temperature to warm the air, so when coolant temperature
is not high, the temperature of delivered warm air will not be high either.
2. Do not use warming device for too long time when the engine is stopped or is running at idle speed.
Otherwise, it will cause too much battery consumption and affect normal driving.
3. When driving at a low speed, remember to engage the transmission to a lower gear to increase
engine speed. And it is the same case with driving on a comparatively long ramp way to reduce
engine's burden.
4. Adjust temperature control knob to cooling area to reduce blast volume, in which case you can
press inner and outer circulation button or turn up fan speed.
5. When heating indoor, A/C switch must be in off position to increase the heating efficiency and
reduce engine's energy consumption. A/C switch is connected when pressed, and disconnected
when sprung back.
Wind Outlet Adjustment
Turning thumb rod and thumb wheel can adjust

wind’s left-right direction; and rotating blades can
adjust wind’s up-down direction.
1. Thumb 2. Thumb 3. Blade

wheel rod
D530.KD5K.H1008 35
Accessory System
Ash Tray
Open the lid along the direction shown by the

arrow when using ash tray.
When cleaning it, first open the lid, and then pull
the whole ash tray out along the direction shown
by the arrow.
Caution:
Close the ash tray for the sake of
safety when leaving the vehicle.
Cigarette Lighter
Press cigarette lighter directly when using it. And

wait for 10s after it is released, it will automatically
spring back to the original position when
resistance wire at the front of the lighter is heated
red. Now you can pull it to light the cigarette. Put it
back after using it.
Warning:
Cigarette lighter must not be
connected for long. If it does not
spring back automatically after a long
time, pull it manually.
Open Type Front Roof Glove Box
The front roof glove box includes left and right

glove box, used to accept books, folders, CD and
other objects, weight of which should not exceed
3kg.
1. Front roof left 2. Front roof right

glove box glove box
36 D530.KD5K.H1008
Berth Reading Lamp (for advanced configuration cab)
It is above the berth and you just need to press

the button on the lampshade to light it. And press
the button again to close it. Repeat the process
like this.
1. Switch
Front Reading Lamp
These lamps are installed on interior front roof.

Press left and right buttons to light left and right
reading lamps and press the buttons again to turn
them off.
DOOR position: pull the switch to DOOR gear,

and interior lamp will be controlled by both sides’
door switch. When the door is open, interior lamp
will turn on; and it will go off when the door is
closed;
ON position: pull the switch to ON gear, and

interior lamp will turn on whichever state the door 1. Interior lamp 3. Right switch
is at. 2. Left switch 4. Reading lamp
OFF position: pull the switch to OFF gear, and

interior lamp will go off whichever state the door is
at.
Step Lamp (for moderate and advanced

configuration models)
It is installed inside the driver’s side door and is for

step lighting. The step lamp is controlled by door
switches. When the door is open, the step lamp
will be on; and when the door is closed, the step
lamp will be off.
1. Step lamp
D530.KD5K.H1008 37
Driver’s Side Glove Box
The driver’s side glove box is used to store cups,

mobile phones and other carry-on small objects.
Working Lamp Socket (for moderate configuration)
This socket provides illumination power supply for

the illuminating lamp used for vehicle overhaul. It
can also be used as external power supply. Power
output of this socket is not controlled by the key
switch but the power switch of the complete
vehicle. The rated load of this socket is 24V, 10A.
Caution:
When using this socket as power
supply, the power consuming load
must never exceed the rated load of
the socket.
1. Working lamp socket
Curtain
1. Upon extending curtain, put the rings on

curtain into corresponding hooks on guide
rail, then evenly extend it, overlap curtains
with fasteners, and clip metal fasteners at
lower part of side/rear curtain onto plastic
buckle on protection board.
2. Upon collecting curtain, first release nylon

buckle, then evenly collect it along guide rail,
and bind it with fastener.
Caution:
Do not use strength on the lower
end of the curtain when unfolding 1. Curtain 2. Buckle
the curtain or stamp on it.
38 D530.KD5K.H1008
Radio Panel Position and Name
1. Power switch 9. Volume increase knob

2. Mute knob 10. Rest knob
3. Display 11. Mode / band knob
4. USB gate 12. MP3 selection previous
5. Set knob 13. MP3 selection next
6. USB play button 14. Clock - F/C knob
7. Radio tuning knob 15. MP3 play previous folder
8. Volume reduction knob 16. MP3 play next folder
Retuning this unit:
1. Retune the unit before using it for the first time or replacing the battery.
2. Retune this unit when its system hangs up.
3. Retune this unit by pressing the reset (RST) button using an object with sharp head.
4. Pressing the reset (RST) button will clear the clock and certain contents stored in the memory.
Caution:
1. Before ejecting or inserting U disc, switch off PWR to prevent file loss or disc
breakage;
2. The downloading format of U disk is MP3. This unit does not support other formats;
3. Inserting a hard disk over 2G into this unit is strictly prohibited to prevent
overcurrent from damaging the unit.
D530.KD5K.H1008 39
Panel Functions
1. Power (PWR) switch button: Press this button to turn off the power. This unit is set such that it will
be turned on when any button is pressed. Press any button on the panel to turn on the power of the
main unit. Then the LCD is turned on, showing the state before last shutdown.
2. Mute button: Press this key to switch off the volume; press it again to resume the volume.
3. USB gate: Open this gate to insert USB unit
4. Audio mode / menu setting knob
a. No matter which working state this unit is in, radio or tape play, short press this knob to realize the
following cyclic setting:
Short press Short press

Short press once once more once more TRE (treble
VOL (volume BAS (bass
adjustment) adjustment) adjustment)
Short press
BAL (left and right sound once more
channel balance
adjustment)
When the LCD shows a certain function, rotate this knob to increase or decrease that function. The
maximum displayed value of VOL is 32, BAS and TRE from -7 to +7, and BAL from -5 to +5.
b. Long press SEL knob to realize the following cyclic setting:
Long press SEL Press once Press once

once more within 3s more within 3s
Press SEL twice more

within 3s
• When the LCD shows DSP OFF, short press VOL+ knob can realize the following audio effect
mode cycle:
Short press VOL+ Short press VOL+
once once more
Display off (tone POP CLASS
effect mode off)
Short press VOL+
ROCK once more
When selecting a certain tone mode without pressing VOL+ knob, it will confirm this tone mode and the
LCD upper will display the characters of this mode; where DSP OFF (tone mode off) is displayed, short
pressing VOL- knob will realize various tone modes conversion as well, however, the mode conversion
sequence is reverse.
• When the LCD shows BEEP OFF, rotate the VOL+ or VOL- knob to enable keystroke sound, which
means a click sound is given when any button is operated; rotate the VOL knob again to disable
the click sound;
• When the LCD shows LOUD OFF, rotate the VOL+ or VOL- knob to enable bass, with LOUD
displayed on the upper right corner of the LCD. Rotate the VOL+ or VOL- knob again to disable the
treble and hide the characters LOUD on the upper right corner of the LCD.
5. USB play knob
40 D530.KD5K.H1008
In MP3 play mode, short press this knob and MP3 play will be paused, the LCD will display PAUSE;
short pressing this knob again and the MP3 will continue to play;
6. Radio tuning knob
Turn the tuning knob to regulate stations of different frequencies, and current station frequency will be
shown on LCD.
7. Volume increase/decrease VOL+/ VOL- knob
In radio or MP3 play mode, pressing VOL+ knob will increase the volume and pressing VOL- knob will
decrease the volume. When turning on this unit again, the volume will be the stated memorized upon
shut down. 32 will be displayed when the volume is the maximum.
8. Reset knob (RST)
• Press the reset knob before using this unit for the first time or replacing the battery;
• When you accidentally make the programs of this unit disorderly, you can also press the reset knob
to restore the programs to the normal state;
• Since this knob is seldom used in normal times, it is designed not to protrude from the panel. You
can insert a stick-shape object into the hole of the RST knob to press it once to reset the unit.
9. Band/mode knob
In play state, short pressing this knob will switch to radio FM band; short pressing it again will switch to
MW band;
10. MP3 song selection Previous / Next knob:
Previous/next song selection: in play mode while there is sound, short pressing the Previous knob will
restore to the song’s start; pressing this knob again will play the previous song; short pressing the Next
knob will select the next song.
11. Clock setting F/C knob
• When this unit is in radio or play mode, the LCD will display the radio frequency or playing time. To
view the current clock, short press this knob once and then the LCD will display the current time
immediately and then restore the original state automatically after 5s; to pass over the 5s automatic
recovery, short press this knob once more and this unit will restore the original state;
• To set or calibrate the clock, no matter what state this unit is in, long press this knob once and this
unit will switch to clock setting. Then the LCD will display the time and the hour zone will flicker.
Press + knob once and the hour number will increase; this knob can be pressed once by once,
namely to increase the time by one hour each time. Alternatively, keep pressing this knob and the
clock will increase continuously. Press - knob and the hour number will decrease. After hour setting,
short this knob once to confirm it and then the hour zone will not flicker while the minute zone will
flicker. At this point, press + knob to increase minute or press - knob to decrease minute. After
setting, press this knob again to confirm it and the minute zone will stop flickering. Then the LCD
will display the set time and restore the operating state before setting automatically after 5s.
Alternatively, short press this knob to restore the operating state before setting immediately;
• This unit allows 12-hour or 24-hour time system, which will memorize the time system used last
time. To switch between 12-hour system and 24-hour system, long press this knob once while the
hour number on the LCD is flickering and 12-hour system will be switched to 24-hour system (AM
means ante meridiem and PM means post meridiem) and AM or PM will disappear as well. Long
pressing this knob once more will switch 24-hour system to 12-hour system.
D530.KD5K.H1008 41
12. Previous folder knob and Next folder knob
In USB state, press this knob to go back to the previous folder or go to the next folder.
Interior Rearview Mirror
Interior rearview mirror can be adjusted to any

angle.
Rearview Mirror and Lower Mirror
Exterior rearview mirrors are installed on both left

and right side of the cab. Front lower mirror,
convex mirror and close-proximity mirror are
installed on passenger side. Convex mirror can be
optionally installed on driver side. The driver can
adjust rearview mirror, front lower mirror and
convex mirror to realize best rearview and under-
view effect.
1. Close-proximity 3. Front rearview

mirror mirror
2. Passenger side
front lower mirror
Comprehensive Alarm
Tail Lamp Detection Function (Only for Main Vehicle, Excluding Trailer)
When any filament of the rear fog lamp, rear position lamp or brake lamp is broken, the filament
detection indicator lamp on the instrument illuminates. This function is used to alert the driver of the
working sate of the tail lamp.
Door Open Alarm Function
When the lamp combination switch is turned to the small lamp position with any door open and the
ignition switch turned to the OFF position, the internal buzzer of the comprehensive alarm sounds. This
function is used to alert the driver to close the lamp when leaving the vehicle.
Multi-purpose Buzzer
Differential Alarm
When the differential switch is pressed, the differential lock starts to act and the multi-purpose buzzer
sounds with a volume of 75dB. The alarm sound consists of a long tone and a short tone occurring
alternately and repeatedly to alert the driver to close the differential switch in time after driving out of a
defective road. Otherwise, the differential will be damaged, causing excessive wear of tyres.
42 D530.KD5K.H1008
Lifting Alarm (for dump chassis only)
When the lifting switch is pressed, the multi-purpose buzzer sounds with a volume of 75dB. The alarm
sound consists of a long tone and two short tones occurring alternately and repeatedly to alert the
driver of safety.
PTO Alarm (for dump chassis only)
When the PTO switch is pressed, the multi-purpose buzzer sounds with a volume of 75dB. The alarm
sound consists of a long tone and three short tones occurring alternately and repeatedly to alert the
driver to turn off the PTO switch in time.
Standby Signal Alarm
When the standby signal is connected, the multi-purpose buzzer sounds with a volume of 75dB. The
alarm sound consists of a long tone and four short tones.
The priority of the buzzer alarm from low to high is as follows: Differential-Lifting-PTO-Standby signal;
Central Distribution Box
When replacing a fuse or relay, it is necessary to confirm the load of the fuse or relay used. Find the
corresponding fuse or relay according to the mark on the nameplate of the central distribution box.
D530.KD5K.H1008 43
Fuse Box Label
44 D530.KD5K.H1008
Relay Box Label
Note: the relay label is on the inner side of passenger side center lower panel.
Adjustment of Steering Wheel
Pull the adjusting handle of the steering column

upward from its locking position. The steering
column can be adjusted upward or downward, and
frontward or rearward for a certain angle. After it is
adjusted to a comfortable position, restore the
adjusting handle to the locking position.
Warning:
Adjusting the position of the
steering wheel is strictly prohibited
during driving.
1. Locking position of steering column adjusting

handle
D530.KD5K.H1008 45
Towing Hook
Before using the towing hook, remove its pin cover

first as follows:
Removal method for driver side towing hood pin

cover
1. Remove the two bolts on the small footrest

using a screwdriver and remove the small
footrest.
2. Rotate the buckle on the towing hook pin

cover 45° using a slotted screwdriver to 1. Small footrest 3. Buckle
remove the towing hook pin cover. 2. Bolt 4. Towing hook pin
cover
Simply follow Step 2 to remove the passenger
side towing hook pin cover.
After using the towing hook, install its pin cover

properly following the above steps reversely.
Front Faceshield
Opening the Front Faceshield
Pheumatic
1. Turn the lock lever at the lower left and right

of the faceshield inward.
2. Pull the lower part of faceshield and it will

open by the action of pneumatic spring.
Manual
1. Turn the lock lever at the lower left and right

of the faceshield inward.
2. Turn on the faceshield and remove the

faceshield internal bracing to support the front
position bracket.
1. Front position bracket
46 D530.KD5K.H1008
Closing the Front Faceshield
1. Raise the faceshield upward slightly, remove

the stay bar from the front stay bar bracket
and fix it to the buckle inside the faceshield.
2. Lower the faceshield slightly and close the

faceshield at the lower left and right
respectively to lock the faceshield.
Fire Extinguisher
The fire extinguisher is located below the

passenger seat. For the detailed operations, refer
to the instructions shown on the tank shell of the
fire extinguisher.
1. Fire extinguisher
D530.KD5K.H1008 47
Cab Tilting
Caution:
1. Park the vehicle on flat ground.
2. Make sure that there is an adequate space for indoor overturning.
3. Reconfirm whether manual valve lever is pulled to the braking position and whether
gear lever is placed at idle position. Block the tyres with triangular fillet.
4. Confirm whether the articles inside cab are arranged properly, and the articles
being prone to falling off in the course of overturning should be stored in a proper
location.
5. Do not drive forward before titling the cab in position. Do not turn the limit lever and
rotate the knob after cab titling. The knob must be in DOWN position during vehicle
driving.
Manual Cab Tilting Operation
Tilt the cab: turn the handle of oil pump to UP

Oil pump
position and then insert the rocker in the rocker rocker arm
Rocker
arm to turn it up and down (see Figure H-D530-
012) . Then the cab will rise slowly until the rocker Shake up and down
cannot move any more.
UP DOWN
Lower the cab: turn the limit handle from A to B Knob

and keep it in position B (see Figure H-D530-013)
and then rotate the knob clockwise to DOWN
position. Then the cab will lower slowly. After the
cab is fully lowered, the hydraulic lock is locked
(see Figure H- D530-014). The release the limit
handle and keep the knob in DOWN position. Limit handle
Latch
Hydraulic lock
48 D530.KD5K.H1008
Adding Fuel
Open the fuel tank cap and add clean fuel of the
specified grade. The fuel tank capacity is 280L.
The fuel charge should not exceed 95% of fuel
tank capacity.
1. Fuel tank cap
Warning Triangle
Warning triangle should be placed 50m away from

the stopped vehicle, easily being noticed by the
drivers of the vehicles behind.
1. Warning triangle
D530.KD5K.H1008 49
Diagnostic Fault Code
Diagnostic Fault Code
1. The on-board and off-board fault diagnosis is designed to make the engine service and
maintenance easier. The electronic subsystem is provided with built-in self-diagnostic capability. It
checks whether signal from the sensor is correct, whether the software operation is normal and
whether the power drive circuit in electronic control module (ECM) presents malfunction.
2. When a fault is detected, it will be recorded in the memory and the engine parameters will be
recorded as well. In addition, different malfunction indicator lamps will turn on according to current
fault type and seriousness. The malfunction indicator lamps include WARN indicator lamp and
STOP indicator lamp. The fault codes can be displayed in the form of twinkling through diagnostic
switch. Diagnostic fault code table (refer to the attached sheet)
Operation instructions
1. The indicator lamp is in off state before fault code recording. Where there is an existing fault code,
the indicator lamp will be on all the time. The working WARN indicator lamp will remind the driver of
existing fault. The vehicle can drive but requires immediate repair. However, a working STOP
indicator lamp will remind of driver stopping the vehicle and repairing it as soon as possible. The
engine warning indicator lamp (WARN) and stop indicator lamp (STOP) can be found on the
control panel in the cab.
Key switch Indicator lamp and state Display information

ON Warning lamp - keeping on There is a fault, the vehicle can drive but needs immediate
ON Stop lamp - keeping on There is a serious fault; park the vehicle in a safe place
and repair it
ON Warn lamp and stop lamp - No fault code
on
ON Warn lamp - stop lamp To indicate the stop lamp is to display fault code again
twinkling at an interval of 1s
Stop lamp - twinkling The twinkling numbers display the fault code in turn, for
example, 244. There is an 1s interval between two code
t i kli
ON Warn lamp and stop lamp - No fault code
keeping on
2. To check the fault code, turn the key switch to OFF position. Then turn the key switch to ON
position. Where there is fault code, STOP indicator lamp and WARN indicator lamp will turn on and
then off in turn and keep off state. Where there is fault code, both indicator lamp will turn on
momently and then display the fault code through twinkling.
50 D530.KD5K.H1008
3. The fault codes will twinkle in the following Pause

Fault code 244
sequence. The WARN indicator lamp will Twinkling once Twinkling once
twinkle first and then pause for 1s or 2s. After
this, the STOP indicator lamp will twinkle the Twinkling twice Twinkling 4 Twinkling 4
recorded fault code at an interval of 1s or 2s. times times
After the STOP indicator lamp finishes the Twinkling once

Fault code 115
Twinkling once
code twinkling, the WARN indicator lamp will
twinkle again. The code consisting of 3 Twinkling once Twinkling once Twinkling 5
numbers or 4 numbers will repeat twinkling in times
the same sequence.

1. Example of fault code twinkling sequence
4. To proceed the next fault code, turn the setting (+)/restore (-) switch to increase (+) position
temporarily and the driver/operator can turn the setting (+)/restore (-) switch to decrease (-) position
temporarily to access the previous fault code. If only one fault code is recorded, no matter whether
the switch is turned to increase (+) or decrease (-), only the same fault code will be displayed.
Caution:
1. Make sure to shut down the diagnostic switch when there is no fault code twinkling.
2. Shut down the diagnostic switch or remove the short circuit plug when not to use
the diagnostic system.
3. The diagnostic switch must be in off state when the engine is running.
Levers
Transmission Control Lever
Be sure to completely depress clutch pedal when

shifting transmission gears. No shift between
forward gear and reverse gear can be performed
before the vehicle comes to a full stop. When gear
lever is moved to R position (reverse gear),
backup lamp turns on, and the buzzer sends an
alarm.
D530.KD5K.H1008 51
Caution:
1. Ensure to release the clutch completely upon gear shifting. The gear lever should
be engaged in position.
2. When shifting from low gear zone to high gear zone (or conversely), the driver
should consciously wait a moment for the shift of a air circuit between high gear and
low gear.
3. Do not shift the high and low gear zone when driving down a slope.
4. Start the vehicle in 1st gear according to the road conditions.
Manual Valve’s Control Handle
Manual valve controlled spring air chamber can be

used as parking brake or emergence brake when
acting upon rear axle brakes. Please pull back
manual valve’s control lever to brake locking
position when parking or emergently braking. Lift
control valve when starting the vehicle and braking
off, so that the control lever will go back to braking
release position.
1. Pull forward to 3. Pull upward

release
2. Pull backward to
brake
Check of Drier
Check the air vessel periodically (one month is

recommended) for water accumulation. Replace
the drier filter cylinder and turn the water drain
valve under the air vessel to drain the water off if
there is water accumulation.
1. Water drain valve
52 D530.KD5K.H1008
Methods to Release Spring Brake
If the spring brake functions automatically, it's

caused by the pressure drop of spring brake air
chamber. Check the pipe system or valves for air
leak, and repair them in time if there is leak. The
method to release the spring brake: turn the spring
brake release bolt anticlockwise with spanner until
the spanner cannot move any more, then the
brake is released.
Warning:
1. It’s only for emergency to release
parking brake. It’s dangerous to use
the vehicle without parking brake,
which may cause severe accident.
2. Afterwards you must find the 1. Spring brake release bolt
reason for deficient spring brake air
pressure for prompt repair. Reset the
bolt after failure is cleared to resume
normal parking brake function.
Rear Guard Rail
The tail section of frame is equipped with rear

guard rail according to the laws. The guard rail
and bracket are provided with lamp reflector.
Where the vehicle is equipped with tilting type
guard rail, the rear guard rail can be adjusted
upward and fixed by pin when driving on the road
with higher trafficability. The guard rail must be
lowered to prevent the light cars driving in by
accident when running on the flat road.
1. Rear guard rail 2. Reflecting mark
D530.KD5K.H1008 53
Start and Drive
Start and Drive

Engine Start
1. Carry out daily inspection.
2. To avoid starter damage, the start engagement time for engine starter should not exceed 30s and
the interval between two successive starts should be 2min.
3. Confirm the transmission gear lever is in neutral position. Do not depress the throttle upon start.
4. Where there presents failure, solve the problem before starting the engine.
5. Shift the throttle to idling position, turn the key switch to ON position and wait the STOP and
WARNING indicator lamp to turn off; and then turn the key switch to START position.
6. Where the engine start fails three times, check the electronic control and fuel supply system. If the
exhaust presents no blue smoke or white smoke during vehicle towing, it means there is no fuel
supply.
7. The pressure gauge must indicate the normal engine oil pressure within 15s after engine start.
Where the warning indicator lamp for low engine oil pressure does not turn off or the pressure
gauge does not indicate oil pressure within 15s after start, shut down the engine immediately to
prevent engine damage. Check whether the oil level in the oil sump is correct.
8. After start, run the engine idling for 3 to 5min at least to guarantee normal lubrication.
9. The engine speed should not be lower than the minimum start speed upon engine start.
10. Replace the battery in time if it's under voltage. To start the vehicle through battery bridging,
connect the batteries in parallel and guarantee proper contact.
11. Do not allow the motor to be in working state after engine running.
Precautions for Use
1. Do not run the engine at low idle speed for a long time (not exceeding 10min). As long time idling
will result in carbon deposit around the fuel injector nozzle and piston ring and cause valve binding,
which may damage the engine.
2. Do not allow the engine throttle full open over 30s at the engine peak torque (refer to the speed at
peak torque on the engine nameplate); otherwise it will result in severe engine damage and impact
the engine service life.
3. Prevent the engine speed exceeding the maximum engine speed; overspeed of engine will result in
serious damage.
4. After engine running under full load, allow it to run at idle speed for 3 to 5min before stopping it.
5. Continuous running of engine with coolant temperature below 60

℃ or above 100℃ w ill dam age
the engine.
6. Check the engine in time in the following cases: misfire, vibration, abnormal noise, leak, abrupt
change of water temperature and engine oil pressure, power drop, powerless operation, increase
of oil and fuel consumption.
7. To assure safety, make sure to depress the clutch pedal when starting the engine.
54 D530.KD5K.H1008
Start and Drive
8. Leave the key in OFF position for 30s at least upnon engine stalling before switching off the power.
9. The engine will reduce fuel supply when the altitude reaches 3,048m.
10. When welding on the vehicle, disconnect the harness of battery and electronic control module joint
first, so as to avoid electronic components damage.
11. Do not clean the engine electronic components with conductive solvents.
Start method when cab being tilted
1. Turn the manual control valve lever to locking

position and place key switch to ON position.
2. Turn transmission gear shift lever to neutral

position; clear those overturn-prone articles
inside cab.
3. Block the wheels with triangle wood.
4. Follow the specified safe operation

procedures to tilt the cab.
5. The auxiliary start and stalling button are

beside the battery. Press the start button to
start the engine.
6. To stop the engine running, turn the key from ON to OFF.

Warning:
1. Do not contact the gear lever when engine operates under cab titling.
2. Do not lower the cab when the engine is working.
D530.KD5K.H1008 55
Start and Drive
Clutch Operation
The following method is recommended in driving the vehicles to shift high speed to low speed or
inversely. After any operation of clutch, do not place the foot on the clutch pedal.
1. Depress the pedal quickly 5. Shift the gear

2. Transmission control lever in neutral gear 6. Release the clutch pedal to half-engaged
3. Release the pedal quickly position quickly and then release the pedal
4. Depress the pedal quickly slowly
56 D530.KD5K.H1008
Start and Drive
Brake Operation
To stop the vehicle smoothly, operate the brake pedal as follows:
1. Depress the brake pedal by 1/2~1/3 stroke at the point 25~35m from the expected stop position.
2. Begin to release the pedal gradually at the point 5~6m from the expected stop position.
3. Depress the brake pedal slightly to stop the vehicle completely when approaching the stop position.
Caution:
1. If the brake pedal is depressed all the time, the vehicle will stop sharply in a short
distance.
2. Avoid "pumping" the brake pedal, as it will bleed the air inside the air vessel and
cause vehicle out of control.
3. Use foot brake when to stop the vehicle by applying brake.
4. Do not apply emergency brake except for emergency. In particular in raining days
when the road surface is slippery, using emergency brake may result in lateral sliding or
other hazardous conditions.
5. After vehicle washing or passing through deep water pit, water may enter the brake
drum and reduce the brake efficiency. Depress the brake for several times while running
at a low speed to evaporate the water and guarantee the normal operation of brake.
Parking
1. Do not stall the engine immediately after stopping the vehicle. The engine must run idling for 3-
5min. Do not stall the engine until the temperature of engine coolant falls.
2. In general, do not stop the vehicle immediately with engine running under full load or at a high
speed. Reduce the speed and load gradually and run the engine idling for 3 to 5min to prevent
supercharger damage due to bearing oil starvation or machine member overheating.
3. Leave the ignition key switch in OFF position for 30s at least upnon engine stalling before switching
off the power.
Slope Driving Method
1. When driving down slope, the engine exhaust brake should be used effectively to keep the speed
of vehicle within the safe range.
2. Engine speed should not exceed 2,850rpm in any case.
3. When driving down a steep slope, control the vehicle speed and engine speed through combined
use of transmission gear engagement and engine or service brake.
4. Test whether the brake works normally before running across a steep or long slope.
5. When high speed gear is shifted to low speed gear, the speedometer must be monitored to check
the speed, and the engine speed should be monitored with engine tachometer.
D530.KD5K.H1008 57
Maintenance and Adjustment

To prolong the lifetime of vehicle, guarantee the safety and pleasure of driving, make sure to perform
careful and periodic maintenance over the vehicle. This manual describes some common maintenance
and adjustment methods. As for more detailed inspection and adjustment as well as the parts
replacement, however, please contact the near Technical Service Center (Station) of Dongfeng
Commercial Vehicle Co., Ltd. of Dongfeng Motor Group Co., Ltd.
Checking and Adding Coolant
Pressure cap
1. To check the coolant level, turn the ignition key to ON position and check whether the coolant level
warning lamp illumines. If the lamp illumines and the buzzer sends out warning signal, please add
coolant. Alternatively, observe the coolant level from the semi-transparent expansion water tank. If
the level is below the MIN scale mark indicated on the tank, please add coolant.
2. Unscrew the pressure cap to fill coolant until the coolant level is above the plug nut A at the
expansion tank side.
3. Tighten the cap and pay attention to the sealing and working conditions.
Caution:
1. Before adding coolant, check whether there is leak in engine and radiator. Repair it
if there is any.
2. It's recommended to use the long acting freezing and corrosion prevention coolant
made by Dongfeng Motor Co., Ltd. Do not use tap water or hard water from well and
river.
3. Drain the coolant off only after the coolant temperature is below 50℃ (b elo w C m ark
on the water thermometer).
58 D530.KD5K.H1008
Radiator Liquor Drainage
Opening of the water drain valve will drain the

coolant in the cooling system off.
Caution:
1. Before adding coolant, check
whether there is leak in engine and
radiator. Repair it if there is any.
2. After filling, tighten the auxiliary
water tank filler cap. In addition to
corrosion prevention deicing fluid,
the engine should be filled with SCA-
DCA4 preservative.
3. Generally do not remove the
pressure valve cap. The pressure 1. Water drain valve
valve cap can be removed only after
the coolant temperature is below
50℃ (b elo w w ater th erm o m eter m ark
C), otherwise, the spraying of high
temperature coolant or steam may
cause personal injury. Dismount the
pressure valve cap slowly to
discharge the cooling system
pressure during the removal of
pressure valve cap.
Maintenance of Air Filter
Inspection and Cleaning Cycle of Filter

Element
Service the filter element upon 10,000km running

or when the air filter clog indicator lamp turns on
(note this lamp on the instrument board in the
case of working on dusty road or in the site).
Generally, only outer filter element can be
cleaned, and the inner element can be replaced
only.
Change Cycle
The inner and outer filter elements must be

replaced at the same time upon 30,000km running
or when the outer filter element has been serviced
for 5 times or more.
D530.KD5K.H1008 59
Replace the Air Filter Element
1. Unscrew the wing nut of filter end cover by hand and remove the end cover.
2. Screw the fixing nut of the filter element out and dismount the filter element.
3. Mount each component in the procedures reverse to removal.
Cleaning Method of Filter Element
Blow 0.5MPa compressed air from inside to outside to clean the filter element.
Inspection Method of Filter Element
Illumine the lamp and place it inside the filter element to check for damage and pinhole. Check whether
the washer is damaged and replace it upon any abnormity.
Caution:
1. Confirm that filter element is mounted properly; otherwise dirt may be absorbed
inside, sharply shortening the engine lifetime.
2. Never clean the filter element with gasoline or water.
3. Pay attention to the breakage when cleaning the cyclone cover.
4. Check the sealing rings when performing installation.
5. Do not remove the air filter with vehicle running.
6. Tighten the filter element and end closure nut, and make sure the sealing ring of the
end closure is properly installed.
60 D530.KD5K.H1008
Engine Lubricating Oil
Change Cycle
Every 10,000km driving
Method to Check Engine Oil Level
1. Keep the vehicle horizontal to achieve the

correct engine oil level.
2. Check the engine oil level at least 10min after

engine stalling. Pull the engine oil scale out,
wipe it with clean rag and fit it to original
position.
3. Pull the oil scale out again and observe the oil
level. The normal level should be between the
two mark lines. Fill clean oil if insufficient and
drain the oil from the oil outlet if excessive.
Caution:
Check the engine oil level in cold
state.
Method to Change Engine Oil
1. Loosen the screw plug of the sealing oil outlet

at oil sump bottom and drain the oil off from
the oil sump in hot state.
2. Wipe the oil draining screw plug and fit it

back. Replace the oil filter and clean the joint
face of filter seat oil seal.
3. Fill new oil as required.
4. Start the engine and check the filter and oil

draining screw plug for leak with engine idling.
Verify the engine oil level at least 10min after 1. Oil sump 2. Oil outlet
engine stopping until the oil level reaches the
normal range.
Caution:
Drain the oil off after the engine
completely stops.
D530.KD5K.H1008 61
Oil Filter
Change Cycle: not more than 10,000km or 3

months
Change Method:
Removal: clean the area around the oil filter first

when to replace the filter. Remove the oil filter by
using dedicated oil filter spanner. Clean the
surface of filter seat gasket.
Caution:
The oil filter O-ring may stick to the
filter seat. Make sure to remove it
before mouting the new filter.
Installation: fill clean oil to the filter and coat the
gasket surface with oil before installation. Then Fasten
mount the filter by hand and tighten it by 3/4 turn
after the sealing surface contacts the joint face.
Fuel Filter
Replacement Cycle: every 20,000km driving
Replacement Method:
Removal: remove the chipping around the fuel

filter seat, disassemble the filter by spanner and
drain the filter.
Installation: lubricate the O-ring seal with clean oil

and fill the fuel filter with clean fuel. Mount the filter
to the filter seat and rotate it until the gasket
contacts the seat face. Tighten the filter by a
further 3/4 turn after the gasket contacts the filter
seat face.
62 D530.KD5K.H1008
Draining of Oil Water Separator
This oil water separator is provided with drain

valve.
Draining Method:
Shut down the engine, open the drain valve to

discharge the water and settling. Tighten the drain
valve when clean fuel flows out.
Daily Maintenance of Turbine Supercharger
1. Check the air filter for clogging.
2. Check whether the pipeline and joint between

the air filter and supercharger compressor
inlet are in good conditions.
1. Drain valve
3. Check whether the clamp at the joint of supercharger and engine intake and exhaust pipe or other
coupling screws get loose.
4. Check the supercharger housing joints for oil leak. Locate the fault cause and eliminate if there is
oil leak.
5. Check the oil inlet and outlet pipeline for damage or restriction.
6. Check the supercharger housing for discoloration, crack or damage caused by overheating, and
replace the housing housing in time if there is any.
7. Do not use the supercharger any more in the event of supercharger abnormal sound. Stop the
vehicle to check it and solve the fault.
8. The user should not disassemble the by-pass valve mechanism or adjust it without permission.
Precautions for Turbine Supercharger Start and Operation
1. For engines whose oil or oil filter are replaced, or engines that are out of use for a long time, crank
them for several times to pre-oil the supercharger before starting the engine.
2. Make sure to use engine oil and diesel oil of speicified grade; pay attention to the variation in oil
pressure within 15s after start. Warm the engine up for 5min at low speed or moderate speed after
start. Pay more attention if the air temperature is low. Run the engine idling for 3 to 5min after start.
3. The supercharger oil inlet pressure should be kept between 2-4 kgf/cm2 during operation.
4. Stop the engine to check in the event of engine oil pressure warning during operation.
5. Note the abnormal sound of supercharger during operation, and solve the fault if there is abnormal
sound.
Precautions for Turbine Supercharger Stop
D530.KD5K.H1008 63
In general, do not stop the vehicle immediately with engine running under full load or at a high speed.
Reduce the speed and load gradually and run the engine idling for 3 to 5min (not exceeding 20min) to
prevent supercharger damage due to bearing oil starvation or machine member overheating.
Adjustment of Valve Clearance
Intake valve 0.254mm
Exhaust valve 0.508mm
The overhead mechanism of engine is free of adjustment.The valve system is designed to require no
valve clearance adjustment during the normal use of the first 241,402km running. The intake valve
clearance is 0.152 to 0.381mm and exhaust valve clearance is 0.381 to 0.762mm, which allow the
normal operation of valve system. It's advisable to adjust the valve clearance at about 241,402km
running and check it once every 81,000km later.
Inspection of Clutch Fluid Level
Normal Change
Every 5,000km running
Under normal conditions, the oil tank level should

be around the scale marks of MAX. Add oil if the
level is below MIN scale mark. Check the pipeline
system for leak before filling oil. If any leak
presents, please repair it before filling oil.
Caution:
1. Do not use brake fluids of
different quality or different grade
and model.
2. Strictly prohibit using mineral
oil as brake fluid and make sure to
use clean brake fluid. 1. Clutch oil tank
3. Do not have the brake fluid
contact any paint surface so as to
avoid damage to paint film.
4. Pay special attention to the
sealing of brake fluid.
5. Do not allow dirt or dust
entering the oil tank.
64 D530.KD5K.H1008
Adjustment of Clutch
The clutch employs hydraulic control system

consisting of master cylinder and booster. Method
of clutch pedal adjustment:
1. Loosen the master cylinder push rod locking

nut, adjust the push rod upward by hand until
the rod cannot move any more, and then
tighten the nut.
2. The booster push rod requires no adjustment. 1. Booster 2. Master cylinder

3. The stroke of master cylinder and booster
push rod is 20 ~ 24mm and 17 ~ 21mm
respectively after the above adjustment.
Clutch Exhaust
Exhaust the air inside the clutch control system in

the following way when there is air in it:
1. Fill the clutch oil tank with brake fluid to make

the air vessel pressure reach 650kPa.
2. Remove the booster dust cup, unscrew the

exhaust bolt of booster and depress the
1. Exhaust hose 3. Liquid tank
clutch pedal repeatedly until bubbles exhaust
2. Exhaust bolt
from the tank.
3. Tighten the exhaust bolt and depress the

clutch pedal repeatedly. Depress the clutch
pedal, unscrew the exhaust bolt to exhaust
the air in the brake fluid and then tighten the
bolt and release the clutch pedal.
4. Repeat Step 3 for several times until no air

exhaust from the exhaust bolt port and the
driver can feel complete clutch release.
D530.KD5K.H1008 65
Inspection of Final Drive Oil Level
Initial Change: 1,500 ~ 2,500km for new vehicle

running-in.
Capacity of rear axle is 13L.
Normal Inspection: every 5,000km maintennace.
Inspection Method: Unscrew the seal screw plug

for oil level inspection hole. The oil level should
reach the lower edge of inspection hole. Add oil if
the level is below the lower edge. Check the
breather plug conditions and rinse it. 1. Oil level 2. Oil drain plug
inspection hole
Normal Change: every 30,000km maintenance.
Change Method: Change the final drive

lubricating oil with engine being hot. Upon change,
first screw off oil drain plug to discharge lubricating
oil and to clean the plug, then install it again, and
fill new oil from oil level inspection hole.
Caution:
1. Avoid the entry of dirt or debris
upon oil filling, and always keep the
breather plug clear.
2. Oil level should be kept at its
normal height; the application may
be affected by too high or too low
oil level.
66 D530.KD5K.H1008
Inspection and Change of Transmission Oil
Initial Change: 1,500~2,500km running-in.
Normal Inspetion: 5,000km maintenance.
Inspection Method: Unscrew the seal screw plug

for oil filling and oil level inspection hole of the
transmission. The oil level should reach the lower
edge of screw plug hole. Add oil if the level is
below the lower edge.
Normal Change: every 25,000km maintenance.

1. Oil filling and oil level inspection hole
Change Method: Replace the transmission
lubricating oil with engine being hot. Upon 2. Oil draining plug screw
replacement, unscrew the oil draining screw plug
to drain the oil in the transmission first, then rinse
the screw plug (the magnet on the plug adsorbs
iron chip accumulated in the oil), fit it back and fill
new lubricating oil through oil filler hole.
Caution:
1. Too low oil level may result in
bearing and gear burning, and too
high level may result in overheating
and oil leak.
2. Always keep the breather plug
clear.
Maintenance of Wheel Hub Bearing
Conduct wheel hub bearing maintenance every

10,000km running. Before assembly, dismount the
wheel and brake drum, clean the hub bearing and
hub cavity, fill the gap between bearing inner race
and holder roller with new grease and apply a thin
coat of grease to the internal and external
surfaces of bearing.
Adjustment of Front Wheel Hub Bearing
1. Tighten the locking nut to 120~150N.m and

rotate the wheel hub by 2~3 turns to contact 1. Wheel hub 3. Locking nut
the bearing completely. 2. Wearing plate
2. Tighten the locking nut to 120~150N.m.
D530.KD5K.H1008 67
3. To achieve correct base bearing pretightening force (20 ~ 55N) and align te split pin and locking nut
bottom cut, it's allowed to rotate the locking nut back by 30° and pass the split pin through to lock.
Adjustment of Rear Wheel Hub Bearing
1. Tighten the adjusting nut and rotate the wheel

to move the bearing to the right position.
2. Then rotate the adjusting nut b hole siteack,

tighten the nut by hand and then loosen the
nut by 2 lock washer hole sites.
3. Mount the oil seal outer race and hub outer oil
seal. Mount the locking washer, tighten the
locking nut to 250 ~ 300N.m and the wheel
should be able to rotate freely without evident
axial float and swing. 1. Adjusting nut 4. Locking washer
2. Oil seal housing 5. Locking nut
4. Check and tighten the axle shaft fixing nut to 3. Wheel hut
40 ~ 100N.m every 5,000km. external oil seal
Caution:
1. Ensure the oil seal edge will not
be broken during hub service.
2. Apply a thin coat of grease to
the two edges of new oil seal when
replacing the hub inner oil seal.
3. After hub bearing adjustment,
note the temperature of hub within
the first 10km running. Where there
is heating occurence, it indicates
the bearing is too tight and should
be readjusted. Align the lock plate
screw and adjusting nut to enable
the minimum looseness of adjusting
nut.
68 D530.KD5K.H1008
Maintenance and Adjustment of Brake
Clearance of brake drum and brake shoe lining: At

the center of brake shoe: 0.3~0.5mm.
Method of local adjustment:
1. Fit the box spanner over the worm shaft head,

rotate the worm shaft to make the lining
contact the brake drum and then rotate the
worm shaft in reverse direction by 1/2 turn.
The brake drum should rotate freely without
contacting any part at this point.
2. Check that push rod travel of brake air

chamber falls within 25±5mm.
Caution:
Attention should be paid to the
followings during adjustment:
1. Do not change push rod travel
through moving connecting fork of
brake air chamber.
2. Upon adjustment of rear brake,
make sure to park the vehicle on a
flat place and ensure the air vessel
pressure above 700kPa.
3. Plug wheel front/rear ends with
triangular fillet, and adjust rear
brake clearance after releasing
parking brake.
D530.KD5K.H1008 69
If the brake is equipped with self-adjusting arm, it

will adjust the clearance between shoe plate and
brake drum smaller to reduce service time and
guarantee driving safety when the friction lining
wear and clearance exceed the set value.
During normal operation, apply grease from the

grease nozzle every 10,000km running. Check the
reverse adjusting torque once every 15,000km
running, namely, rotate the worm shaft in the
direction enlarging the brake clearance (repeat
this test 3 times). If each torque is less than
26N.m, the arm must be replaced. In addition,
check the brake part assembly for smooth return
and binding during operation.
1. Small pin roll 4. Connecting yoke
Release the parking brake before driving on the 2. Worm shaft 5. Locking nut
road and apply the brake for 30 ~ 40 times within 3. Grease nozzle
300kPa ~ 400kPa air pressure to adjust the
excessive brake clearance smaller automatically.
Check the brake friction lining wear conditions

periodically to prevent brake efficiency reduction
and damage of other parts due to excessive wear
of friction lining.
To replace the shoe plate, rotate the worm shaft to

make the camshaft in minimum opening position.
After friction lining replacement, apply the brake
for 30 ~ 40 times within 300kPa ~ 400kPa air
pressure range to ensure the brake clearance is
smaller. The shoe plate clearance will keep
adjusting automatically along with vehicle running-
in until it is stable in the preserved design
clearance range.
Manual Adjustment of Brake Clearance
After the new vehicle or new friction lining being

put in service, if the abnormal clearance between
brake shoe and drum and the new friction lining
expands due to being heated or driving in
mountainous district (frequent brake application)
result in too small clearance and impact the
normal use, adjust the clearance larger manually.
70 D530.KD5K.H1008
1. Fit the box spanner over the worm shaft head of self-adjusting arm, rotate the worm shaft to contact
the lining with brake drum and then rotate the worm shaft in reverse direction by 1/2~2/3 turn (the
torque to rotate the worm shaft reversely will be larger). The brake drum should rotate freely
without contacting any part at this point. Or, measure the clearance using a feeler gauge and adjust
the brake clearance to appropriate range (0.6~1.0mm).
2. Check whether the brake air chamber push rod stroke is within 30±5mm (at a pressure of 300kPa).
3. In case the worm shaft cannot be rotated due to long service time of the self-adjusting arm or lack
of due maintenance and lubrication, remove the small pin roll of the self-adjusting arm and carry
out Step 1 and 2 to solve the problem. At this point, the adjusting arm has no self-adjusting function
and it should be repaired in repair service station in time or replaced.
Caution:
1. Prohibit manual adjustment of brake clearance except for the above cases;
2. Regularly check the wearing plate so as to prevent brake failure due to excessive
wearing;
3. Upon manual adjustment of brake clearance, do not change push rod stroke
through turning the connecting fork of brake air chamber;
4. When manually adjusting the rear brake, make sure to park the vehicle on level
ground and make sure the pressure in air vessel is above 700kPa.
5. Fix the wheels with triangle fillet from front and hind, the rear brake can only be
adjusted after releasing the parking brake.
6. Under abnormal circumstances of self-adjusting arm, make sure to stop the vehicle
to check the self-adjusting arm and other parts of brake system and take proper
measures to eliminate the failures.
Inspection of Brake Pedal Stroke
1. Depress the brake pedal slightly to check the

free stroke. The normal value should be
12~18mm.
2. There should be no binding occurence when

the brake pedal is depressed to the end.
3. There should be exhaust sound when the

pedal is released.
D530.KD5K.H1008 71
Adjustment of Front Wheel Toe-in
Check and adjust front wheel toe-in upon every

15,000km maintenance. The recommended front
wheel toe-in of this vehicle is 0~2mm. Adjust the
front wheel toe-in as following:
1. Park the vehicle on the flat ground and jack

the front axle to keep the wheels in straight
driving position;
2. Loosen the tie rod clamp bolt and rotate the

tie rod with pipe pliers to adjust the required
toe-in.
3. During adjustment, mark the tread pattern

center of left and right tyres and measure
value B right ahead of the front axle and then
turn the mark to the back to measure value A.
4. The difference of value A and B is the toe-in.

Tighten the clamp bolt after adjustment.
72 D530.KD5K.H1008
Inspection and Change of Power Steering Hydraulic Oil
Clean the oil tank before checking the oil level.

Then unscrew the oil scale assembly, clean and
refit the scale, then take down it, and check oil
level. If the oil level is out of the range between
the upper and lower scale marks of the oil scale,
add hydraulic oil of the same model.
Inspection cycle: every 5,000km running.
Initial change: the first 5,000km running.
Change cycle: every 20,000km running.
Change Method:
1. Block the rear wheels of the vehicle with 1. Oil gauge

triangular fillet front and back, shift the
transmission to neutral gear, jack the front
axle to raise the tyres of both sides off the
ground.
2. Unscrew the steering gear inlet and outlet oil

pipe joints to drain the oil of steering system
off and start the engine and rotate the
steering wheel to and fro at the same time.
3. Ensure the system has drained the oil off,

open the oil tank cap and replace the
hydraulic oil filter element.
4. After filter element replacement, fill the oil

tank and start the engine in short time to run
the engine idling, then fill hydraulic oil after
stalling the engine. Repeat this for several
times until the hydraulic oil level is between
the lower and upper scale marks of oil gauge.
Caution:
1. Do not fill hydraulic oil with
engine running.
2. With engine idling, rotate the
steering wheel back and forth so as
to facilitate air exhaust in the
system.
3. Engine must be stopped upon
oil level check.
D530.KD5K.H1008 73
Inspection of Steering Wheel Free Rotation
Upon 5,000km maintenance, check the free

rotation of steering wheel, and leftward/rightward
free rotation at middle position should not exceed
15°. Perform the following adjustment upon
excessive free rotation:
1. Check and adjust the front wheel hub bearing

clearance.
2. Check whether the drag link and tie rod joints

get loose and adjust them upon looseness.
Adjust the drag link joint as following: screw
the screw plug to the end with special bent
spanner and then screw back by 1/4~1/2 turn
and lock the screw plug via split pin.
3. Check the fitting conditions of the ball pin

cone of tie rod and drag link and counterbores
of the upper and low arm, tighten the ball pin
nut, knock the joint fitting position and screw
the nut in by 1/3~1/2 turn to allow the
insertion of split pin exactly. Do not screw the
nut back for insertion of split pin.
4. Check whether the joint of drop arm and

steering gear rocker shaft spline and their
fixing bolts get loose.
5. Check and adjust the meshing conditions of

steering gear rocker shaft and rack piston.
Inspection and Maintenance of Battery
Disconnect the main power switch before

inspection and maintenance of battery.
Inspection of Electrolyte Level
Check electrolyte level every 5,000km running.

The normal level should be 15~20mm above the
pole plate. If the level is low, fill distilled water and
charge over half an hour to mix the added distilled
water with the original electrolyte.
1. Electrolyte
74 D530.KD5K.H1008
Inspection of Electrolyte Specific Weight
Check the electrolyte specific weight once every

15,000km running. Check with gravimeter. The
normal electrolyte gravity falls within 1.26~1.265
(electrolyte temperature is ℃),20 and battery
recharging must be made if the gravity is les than
1.22.
1. Floater 2. Level
Fuse
Confirm the specification of fuse used before

replacing the fuse. If the new fuse is very easy to
burn out, then locate the fault cause and eliminate
it. In case of troubleshooting failure, contact the
nearest Technical Service Center (Station) of
Dongfeng Motor Co., Ltd.
Caution:
Use of plain conductor or other
rated load fuse is strictly
prohibitted.
D530.KD5K.H1008 75
Positioning of the Light
Positioning of the Light in the Cab
1. Front combination lamp: two, bilateral symmetry, including the front turn lamp, front position lamp,
high beam and high/low beam;
2. Front fog lamp: two, bilateral symmetry;
3. Front outline lamp: two, bilateral symmetry;
4. Side turn lamp: two, bilateral symmetry.
76 D530.KD5K.H1008
Rear Combination Lamp
1. Rear fog lamp
2. Back up lamp
3. Position lamp
4. Stop lamp
5. Turn lamp
6. Side marker lamp
7. Rear retro-reflector (left combination lamp)
The right combination lamp is in symmetry with

the left one. Refer to the actual vehicle.
License plate lamp
Method of Adjusting Light
General Adjustment
Park the vehicle on a dark, straight and level road, turn the lamp light switch to low beam gear and
rotate the outside head lamp adjusting hand wheel to adjust the low beam light shape. After adjustment,
turn the lamp light switch to high beam gear and rotate the outside high beam to adjust the high beam
light shape. Then block the ajusted outside head lamp with paperboard and rotate the adjusting screw
of inside head lamp to adjust the high beam light shape.
D530.KD5K.H1008 77
Standard Adjustment
Preparation
1. The site for lamp light adjustment should be level and the screen used should be vertical to the site.
2. The vehicle should be of zero load with one driver inside and normal tyre pressure.
3. The vehicle should be vertical to the screen and the reference center of head lamp should be 10m
away from the screen.
4. Make a horizontal reference line on the screen. The height of reference line should be the same as
headlamp center ground clearance. Record this height as H. Mark the position line for the left and
right headlamp reference center on the horizontal reference line according to the position of vehicle
headlamp.
Ajust the low beam before adjusting the high beam.
1. Low beam
Project the low beam to the screen, and ensure:
1. The height of the cut-off line angle or the center point of the low beam should be 0.6H~0.8H.
2. The left deflection in horizontal direction should not be greater than 170mm and the right deflection
should not be greater than 350mm.
2. High beam
Project the high beam to the screen and ensure:
1. The height of beam center is 0.8H ~ 0.95H.
2. The left deflection of left high beam in horizontal direction should not be greater than 170mm and
the right deflection should not be greater than 350mm.
3. Both left and right deflection of right high beam in horizontal position should not be greater than
350mm.
Left high beam
Left deflection <170mm Right high beam
Side deflection Right low beam
Right deflection
<350mm Left deflection <170mm
<350mm
Left low beam Right deflection <350mm
Left deflection <170mm
Reference
Right deflection
line
<350mm
Lamp
ground
clearance H
Low beam cut-off High beam

Photometry
line angle Beam center (high light)
screen
78 D530.KD5K.H1008
Auxiliary Power Starting
1. Charged battery 2. Uncharged battery 3. Frame
In case the battery is uncharged and the engine cannot start, start the engine using auxiliary power.
Connection procedures:
1. Stall the engine of the vehicle equipped with charged battery.
2. Connect one end of the booster cable (red) to the uncharged battery positive post and connect the
other end to the charged battery positive post. Connect one end of the booster cable (black) to the
charged battery negative post and connect the other end to the vehicle chassis which is equipped
with uncharged battery. Keep away from the battery.
3. After connecting the booster cables, start the engine of vehicle equipped with uncharged battery.
Where it's difficult to start the engine due to too low air temperature, run the engine of normal
vehicle for a few minutes before starting the above said engine.
4. After engine start, remove the cables in the procedures reverse to the wiring procedures.
D530.KD5K.H1008 79
Disassembly and Assembly of Spare Tyres
The spare tyre is mounted to the tail of frame.

Remove and install the tyre in the following way:
1. Unscrew the long safety threaded sleeve,

rotate the rocker counterclockwise with
spanner or pry bar to lower the spare tyre,
take the bracket out and pull the spare tyre
out for use.
2. Mount the spare tyre in reverse procedure.

1. Long threaded 2. Washer
sleeve
Tyre Inflation Device
Tyre inflation device is a kind of equipment to

inflate the tyre via air inflation valve from the air
vessel directly.
The operation procedures are as following:
1. Unscrew the plug of air inflation valve,

connect the tyre inflation hose and air inflation
valve and tighten the joint.
2. Start the engine to operate the air

compressor. Keep the engine running at a
moderate speed during inflation.
3. After the pressure inside the air vessel rises

to 6.5×100kPa, align the other end of inflation
hose to the tyre valve to inflate and measure
the pressure using a manometer to ensure
the tyre pressure reaches the specified value.
4. Remove the inflation hose, tighten the air

inflation valve cap, and then stop the engine.
80 D530.KD5K.H1008
Change of Tyre
Removal of Tyre
1. Block the rear wheels (front wheels) with

triangular fillet front and back upon removal of
front wheels (rear wheels).
2. Unscrew the wheel nuts using the wheel nut

socket spanner in the driver tools.
3. Jack one end of the axle shaft up to raise the

wheel off the ground a little.
4. Remove the wheel nuts.

Jack the front axle
Mounting of Tyre
1. Fit the tyre rim bolt hole over the wheel hub
bolt using a pry bar.
2. Adjust the wheel hub bolt to the bolt hole

center and tighten the wheel nut.
3. Lower the jack slowly to make the tyre contact

the ground.
4. Tighten the wheel nuts to 450~550N·m in

three steps.
Caution:
1. Tighten the wheel nuts crosswise.
D530.KD5K.H1008 81
Recommended Tyre Use and Maintenance

Model Dump truck Truck Tractor Truck
Position Steering shaft Driving shaft Steering shaft Driving shaft Steering shaft Driving shaft
Longitudinal Longitudinal Longitudinal

grooved grooved grooved
National Longitudinal Longitudinal Longitudinal
pattern or dual pattern or pattern or dual
highway pattern pattern pattern
purpose tread longitudinal purpose tread
pattern pattern pattern
Longitudinal Longitudinal Longitudinal Longitudinal Longitudinal
Off-road
grooved grooved grooved grooved grooved
General pattern or
pattern or dual pattern or pattern or dual pattern or dual pattern or
conditons transverse
purpose tread longitudinal purpose tread purpose tread transverse
pattern
pattern pattern pattern pattern pattern
Longitudinal
Transverse Off-road Off-road
grooved
Poor road pattern or dual pattern or pattern or
pattern or dual - -
conditions purpose tread transverse transverse
purpose tread
pattern pattern pattern
pattern
Caution:
1. Longitudinal pattern is not suitable for unpaved road or poor road conditions;
transverse pattern is not suitable for high speed driving.
2. The tyre pressure should not be too high on poor conditions. Tyre pressure is the
key factor for radial tyres: too low pressure will result in early damage of tyres; too high
pressure will result in tyre damage and burst.
3. In general, the front wheel tyres abrasion will be 20 ~ 30% less than that of rear
wheel tyres. To prolong the service life of tyres, interchange the wheels as required
every 8,000 ~ 10,000km driving.
82 D530.KD5K.H1008
Interchanging of Wheels
Perform interchanging of wheels according to the

figure upon each 15,000km maintenance.
Principle of interchanging wheels:
1. With respect to rear axle twin tyres, the

outside diameter difference of the tyres
should not be greater than 12mm and the
smaller tyre should be mounted inside.
2. The front wheels should be equipped with

tyres of same model with even and less wear.
Subject the front wheel tyres of newly
interchanged or assembled to balance test
where possible.
3. After interchanging, the rotation direction of

tyre should be reverse to that before
interchanging. The new tyres must be used in
pairs.
4. The identical axle shaft must be equipped

with tyres of same specification and tread
pattern, otherwise, brake off tracking, vehicle
body swing, tyre burst and steering
malfunction may occur.
5. Check the threads of wheel hub bolts and

wheel nuts for nick. For the sake of safety,
replace the nut and bolt in pairs upon
detection thread damage, since the other
component may be damaged as well.
6. Check the contact face (spherical face) of

wheel rim and mounting holes for deformation
or damage. Replace the wheel rim upon any
deformation or damage. Where the surface of
wheel nut is damaged, the nut should be
replaced.
7. Check the wheel rim and replace it upon

detection of crack.
8. Separate the valve core of inside and outside

tyres for easy inflation during installation of
twin tyres.
Inspection of Tyre Pressure and Tyre Tread
1. Use air gauge to check whether each tyre pressure meets the requirements, and inflate if
necessary.
2. Check whether there is foreign matter attached to the tyre tread and remove it if any.
3. Check the depth of tread pattern. The tyre must be replaced if the depth is less than 1.6mm (less
than 2.4mm on the freeway). Measure six points along the tyre circle as a minimum.
D530.KD5K.H1008 83
Periodic Maintenance Schedule

Inspection and Maintenance Term
This maintenance schedule shows the inspection and maintenance items and terms for the first cycle;
the second cycle is the same as the first one except for excluding the running-in maintenance. The
inspection and maintenance term is indicated in running distance and months. Conduct the relevant
maintenance whichever occurs first. The user should perform maintenance according to the
maintenance parts and distance interval or months in pursuance of the maintenance specification.
Caution:
When conducting vehicle maintenance according to the specified items, the user
should properly shorten the maintenance distance interval in light of the severe
operating conditions in the region where he is to achieve more reasonable vehicle
maintenance and better reliability. In no case, however, should the maintenance
distance interval be prolonged.
The meanings of symbols in the maintenance schedule are as following:
1. A indicates total driving mileage (×1,000 km).
2. B indicates month.
3. ★ indicates norm alrunning m aintenance item s.
4. ☆ indicates running-in maintenance items.
5. △ indicates running-in maintenance mileage (1,500~2,500 km).
Engine
A △ 5 10 15 20 25 30 35 40 45 50 55 60
Inspection and Maintenance Item
B 1 2 3 4 5 6 7 8 9 10 11 12
Clean the engine assembly ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Change the engine oil ★ ★ ★ ★ ★ ★
Check the belt tensioner ★
Check the fuel injection pump ★ ★ ★ ★ ★ ★
Check the air compressor ★ ★ ★ ★ ★ ★
Check the intake pipe ★ ★ ★ ★ ★ ★
Check the air-air intercooler ★ ★ ★ ★ ★ ★
Check the intake pipe ★ ★ ★ ★ ★ ★
Check the fan hub ★
Check the belt ★
Check the overhead mechanism valve
★ ★ ★ ★
clearance
84 D530.KD5K.H1008
Engine
Check for coolant leak ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the engine for oil leak ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the oil cleaning degree and residual
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
amount
Check for fuel leak ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the acceleration and deceleration
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
performance and exhaust conditions
Replace the oil filter ★ ★ ★ ★ ★ ★
Check the air filter resistance ☆ ★ ★ ★ ★ ★ ★
Replace the fuel filter ★ ★ ★ ★ ★ ★
Replace the fuel prefilter ★ ★ ★
Replace the air filter element ★
Tighten the cylinder head and various bolts ★
Check whether the radiator operation is
★
normal
Check the thermostat function ★
Check the antifreezing agent ★ ★ ★
Check the fan shaft and bolts ★
Check the air compressor locking bolts and
★ ★ ★ ★ ★ ★
nut and brake system for leak
Caution:
1. Carry out cleaning or replacement in time if warning signal presents before check and
replacement cycle.
2. Check the vibration damper once every 90,000.00km driving.
3. Replace the deicing fluid once every 90,000.00km driving.
Clutch
A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Check whether the clutch working condition is
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
normal
Check the clutch pedal free stroke ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the clutch hydraulic system for oil leak ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the clutch oil tank hydraulic oil volume ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Change the clutch hydraulic oil ★
D530.KD5K.H1008 85
Transmission
A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the transmission for oil leak ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Clean the transmission and breather plug and
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
check the oil level
Change the transmission oil ☆ ★ ★
Check the control mechanism for malfunction
☆ ★ ★
or breakage
Check the working conditions of transmission
★
bearings
Brake System
A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the brake pedal free stroke ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the efficiency of service brake and
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
parking brake
Check the air lines and valves for air leak ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the brake clearance ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the air vessel for water accumulation ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the tightening conditions of brake back
☆ ★ ★ ★ ★ ★ ★
plate
Check the air compressor locking bolts and
★ ★ ★ ★ ★ ★
nuts
Check the reverse adjustment torque of self-
★ ★ ★ ★
adjusting arm
Check the wear conditions of brake shoe
★ ★ ★
friction lining
Check the wear conditions of brake drum ★ ★ ★
Check the working conditions of air
★
compressor
Check the working conditions of air drier ★
Check and service each valve assembly ★
Steering System
A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the steering gear for oil leak ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the free stroke and operation of
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
steering wheel
Check the connection and fastening conditions
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
of each component
Check the tightening conditions of grips of
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
steering tie rod and drag link
86 D530.KD5K.H1008
Steering System
Check the tightening conditions of steering
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
gear and bracket etc.
Check the steering gear for oil starvation ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the tightening conditions of steering
☆ ★ ★ ★ ★ ★ ★
knuckle arm and drop arm
Check and adjust the front wheel toe-in ☆ ★ ★ ★ ★
Replace the hydraulic oil and oil tank filter
★ ★ ★
element
Check the steering gear for internal leak and
★
check the gear clearance
Check the front wheel alignment ★
Check and adjust the steering gear ★
Check whether the operation of hydraulic oil
★
pump is normal
Suspension System
A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the fastening conditions of plate spring
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
U bolts
Check the plate spring for breakage ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Clean the front and rear plate spring and
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
damper
Tighten the plate spring U bolt under full load ☆ ★ ★ ★ ★ ★ ★
Check the damper for damage and loose ☆ ★ ★ ★ ★ ★ ★
Check the damper for failure ★
Check the spring clamp for loose and
★
deformation
Check the left and right plate spring for flexure
★
and limiting device
Driving Shaft
A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the connections of driving shaft for
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
loose
Check the driving shaft cross axle bearing for
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
loose
Check the driving shaft for offset ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the wear conditions of driving shaft
★
spline
D530.KD5K.H1008 87
Wheel and Axle

A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the conditions of front axle, rear axle
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
and wheel assembly
Check and add rear axle oil ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the tightening conditions of axle shaft
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
bolts and wheel nuts
Check the tyre pressure ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the tyre for abnormal wear ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the rim assembly for breakage and
★ ★ ★ ★ ★ ★
deformation
Check and adjust the hub bearing clearance
★ ★ ★ ★ ★ ★
and lubrication
Interchange of wheels ★ ★ ★
Change the rear axle final drive oil ☆ ★ ★
Check the rear axle final drive and bearing ★
Electrical System
A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the generator efficiency ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the battery electrolyte level (fill it if
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
required)
Check the connection of electric wiring
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
components
Check the working conditions of each lamp
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
and relay
Check the specific weight of battery electrolyte ★ ★ ★
Miscellaneous
A △ 4 8 12 16 20 24 28 32 36 40 44 48
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the vehicle frame rivets for looseness ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the tilting locking device efficiency ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the cab connections for loose ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check the leak and sealing conditions of
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
hydraulic system
Clean the filter screen of oil tank ☆ ★ ★ ★ ★ ★ ★
Check and adjust the carriage tightening latch ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
88 D530.KD5K.H1008
Miscellaneous
A △ 4 8 12 16 20 24 28 32 36 40 44 48
B 1 2 3 4 5 6 7 8 9 10 11 12
Check the carriage longitudinal and cross
★ ★
beams and connecting pieces
Check the wear of carriage tightening latch
★
and replace it if necessary
Periodic Renewal Part
Periodic renewal part means the part service performance of which will certainly reduce along time. The
performance of such parts cannot be predicted to ensure safe driving during general periodic repair and
inspection, and should be replaced by reliable components to guarantee driving safety.
Renewal Cycle (year) 1 2 3 4 5 6 7 8 9 10 11 12

Rubber hose of the power steering hydraulic
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
system
Rubber parts of brake system valves ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Rubber hoses of brake system ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Rubber cup and sealing ring of brake air
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
chamber
Rubber hose of air compressor ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Rubber hose of clutch control system ★ ★ ★ ★ ★ ★
Rubber seal ring of clutch master cylinder ★ ★ ★ ★ ★ ★
Fuel hose ★ ★ ★ ★ ★ ★
Grease Filling Mileage Schedule
Apply grease to each part of the vehicle periodically. Clean the grease nipple and lubricating part before
applying grease. Scrape off the surplus grease after application and fit the nipple cap back if any. Below
table shows the maintenance lubrication for one mileage cycle. Perform maintenance according to the
mileage interval or year shown in this table later.
The meanings of symbols in the table are as following:
A indicates total driving mileage (×1,000 km).
B indicates month.
★ indicates normal running maintenance items.
☆ indicates running-in maintenance items.
D530.KD5K.H1008 89
△ indicates running-in maintenance mileage (1,500~2,500km).
A △ 5 10 15 20 25 30 35 40 45 50 55 60
B 1 2 3 4 5 6 7 8 9 10 11 12
Door hinge ☆ ★ ★ ★
Transverse steering drag link ball pin
Steering knuckle king pin ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Steering driving shaft sliding yoke and cross
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
axle bearing
Front/rear plate spring hanger pin and bracket
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
pin
Driving shaft intermediate support ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Driving shaft sliding yoke and cross axle
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
bearing
Clutch release bearing ★
Front/rear brake adjusting arm ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Trip shaft ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Carriage back plate rotating shaft ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Wheel hub bearing ☆ ★ ★ ★ ★ ★ ★
Cab tilting locking mechanism ☆ ★ ★ ★ ★
Cab tilting torsion bar arm bearing point ☆ ★ ★ ★ ★
Door hinge ☆ ★ ★
Water pump bearing ☆ ★ ★
Generator bearing ★
Starter bearing ★
Door lock, window winder and odometer
★
flexible shaft
90 D530.KD5K.H1008
Maintenance and Adjustment Data

Engine Section
Intake valve clearance 0.254mm
Exhaust valve clearance 0.508mm
Minimum oil pressure of engine idling 69kPa
Minimum oil pressure of engine running at rated speed 207kPa
Engine oil regulating valve opening pressure 352 kPa
Oil filter pressure difference upon by-pass valve open 345 kPa
Fuel injection pump inlet temperature range -30~80 ℃
Engine idling speed 600~800r/min
Minimum starting speed of engine 150r/min
Oil temperature 120 ℃
Thermostat standard regulating range (coolant) 83~95 ℃
Maximum allowable working temperature (coolant) 100 ℃
Recommended minimum working temperature (coolant) 71 ℃
Maximum coolant pressure 200kPa
Recommended pressure cap minimal pressure 50kPa
Maximum temperature of top water tank coolant 100 ℃
Minimum initial temperature of thermostat 81 ℃
Maximum initial temperature of thermostat 83 ℃
D530.KD5K.H1008 91
Chassis Section
Free stroke of steering wheel 15°
Toe-in 0 ~ 2mm
Clutch pedal free stroke 10 ~ 20mm
Clutch booster push rod stroke 17 ~ 21mm
Brake pedal free stroke 12 ~ 18mm
Front/rear brake chamber push rod stroke (manual adjusting arm) 25 ± 5mm
Front/rear brake chamber push rod stroke (self-adjusting arm) 30 ± 5mm
Clearance between front/rear brake shoe plate and brake drum (manual
0.3 ~ 0.5mm
adjusting arm)
Clearance between front/rear brake shoe plate and brake drum (self-
0.8 ± 0.2mm
adjusting arm)
Tensile force after front hub bearing adjustment (at the tyre nut) 25 ~ 55N
Tensile force after rear hub bearing adjustment (at the tyre nut) 29 ~ 88N
Rotating force of final drive Joint flange bolt hole of rear axle 44 ~ 74N
assembly after adjustment
Driven wheel bolt 78 ~ 118N
Driving gear bearing pre- Excluding oil seal resistance 20 ~ 44N
tightening load (joint flange bolt
hole of rear axle) Including oil seal resistance 30 ~ 60N
Final drive driving and driven gear clearance 0.3 ~ 0.4mm

Differential gear clearance 0.2 ~ 0.4mm
Front and back adjustment distance of steering wheel 80mm
Up and down adjustment distance of steering wheel 50mm
92 D530.KD5K.H1008
Tightening Torque
Engine Section
Component or Assembly Tightening Torque (N.m)
Air compressor mounting nut 77
Cylinder head - pressure testing device fixing nut 80
Rocker arm type housing 10/24
Crankcase vent pipe 7
ECM cooling plate mounting bolt 10/24
Fuel filter seat support 27
Injector pressure plate 3.5
Fuel rail bolt 24
Fuel pump mounting nut 24
Fuel injector supply line 22
Oil cooler bolt torque 24
Oil sump bolt torque 24
Oil sump oil drain screw plug (M22) 80
Oil sump oil drain screw plug (M18) 60
Rocker box cap 24
Rocker box housing bolt 24
Rocker arm adjusting screw locking nut 24
Rocker arm support bolt 36
Starter mounting bolt 43
Water inlet joint bolt 43
Water outlet joint bolt 10
Water pump mounting bolt 24
Oil pressure regulating valve screw plug 80
Oil pressure switch torque (in the cast iron
16
component)
Oil pressure switch torque (in the aluminum
10
component)
Mounting bolt of belt driving fan hub (M6) 10
Belt tensioner mounting bolt 43
Fan pulley bolt torque (M6) 10
D530.KD5K.H1008 93

Cooling fan (M6) 10
Cooling fan (M10) 43
Cooling fan (M12) 77
Intake system clamp torque 10
Turbine exhaust pipe clamp torque 10
Turbine supercharger mounting nut torque 43
Turbine supercharger compressor air outlet elbow
8
torque
Turbine supercharger oil supply line torque 20
Intake and exhaust pipe torque 8
Turbine supercharger oil return pipe 23
Charger mounting bolt 40
Charger regulating lever bolt 24
Engine front lifting eye mounting bolt 113
Engine rear lifting eye mounting bolt 113
Engine front suspension bracket mounting bolt 77/150/350
Flywheel bolt torque 30
Flywheel housing bolt torque (M10) 49
Flywheel housing bolt torque (M12) 85
Flywheel gear ring 30
Chassis Section
Tightening Position Tightening Torque (N.m)
Half axle fastening bolt 140~180
Front/rear tyre fixing nut 450~550
Final drive driving gear flange fork nut 400~540
Steering gear bracket fastening bolt/nut 210~280
94 D530.KD5K.H1008
Front/rear shoe plate shaft locking bolt 50~70

Fastening bolt of transmission and clutch housing 140~170
Fastening bolt of clutch and flywheel 40~60
Ball head pin fixing nut of drag link ends 250~310
Upper fastening bolt/nut of steering gear bracket and
210~280
frame
Fastening bolt of steering gear and steering gear
380~550
bracket
Steering wheel locking nut 170~250
Connecting nut of driving shaft cross axle flange fork 160~240
Fastening bolt of rear axle differential housing 160~200
Fastening bolt of differential bearing cap 350~400
Fastening bolt of final drive driven gear and
600~700
differential housing
Fixing bolt of rear axle final drive housing 140~170
Locking nut of rear axle final drive driving gear flange
400~550
fork
Fastening bolt of front brake back plate 160~220
Fastening bolt of rear brake back plate 75~123
Front plate spring U bolt/nut 350~400
Rear plate spring U bolt/nut 450~500
Fixing nut of front brake back plate 160~220
Locking nut of tie rod 50~60
D530.KD5K.H1008 95
Bulb
Position Model
High beam H1 (70W)
Low beam H14 (70W/75W)
Front combination lamp
Front turn lamp P21W
Front position lamp W5W
Front fog lamp H3 (70W)
Side turn lamp PY 21W
Front outline lamp R5W
License plate lamp R5W
Turn lamp P21W
Stop lamp P21W
Side marker lamp R5W
Rear combination lamp
Position lamp R5W
Rear fog lamp P21W
Back-up lamp P21W
Warning indicator lamp TLXX1100
Combination instrument
Instrument board lamp TLXX1100
96 D530.KD5K.H1008
Capacity Data
Oil Filling Part Oil Grade Charge Amount (L)
Engine oil capacity (overall system) CH-4 diesel engine oil 15-17.5
Diesel oil tank Diesel oil (CHN 3) 280
DF6S650 6-gear 85W/90 MT-1 moderate load vehicle gear oil
7.5
transmission
Rear axle 85W/90 GL-5 heavy load vehicle gear oil 13
Power steering system (overall system) DFL-L20 diesel engine oil 2.5
Clutch oil tank Synthetic brake fluid 1.0
Cooling system Long acting corrosion prevention deicing fluid Adding to 2/3 full of
auxiliary water tank
Oil and Grease
Engine oil and steering gear oil
Dongfeng Cummins Engine Company

recommends high-quality SAE15W-40 heavy load
oil of CH4/SJ, CG-4/SH, CI-4/SK and CF-4/SJ
grade.
It's recommended to use Dongfeng dedicated

engine oil.
The recommended temperature range of use is

shown in the figure:
Designated Product
Genuine Dongfeng Dongfeng Commercial Vehicle Co. Ltd of

spare parts Dongfeng Motor Co. Ltd.
(Dongfeng
dedicated oil)
Transmission Oil
The transmission uses 85W/90 MT-1 manual

transmission oil and the user may use GL-4 grade
or above vehicle gear oil of different viscosity
grade to replace it according to the local
atmospheric temperature.
D530.KD5K.H1008 97
Designated Product

(Dongfeng
dedicated oil)
Fuel
Use CHN 3 diesel oil. The user may select acceptable diesel oil of different grades according to local
atmospheric temperature. Recommended temperature range:
0# light diesel oil: used in region with atmospheric temperature above 4℃
-10# light diesel oil: used in region with atmospheric temperature above -5℃
-20# light diesel oil: used in region with atmospheric temperature above -5℃~ -14℃
Rear Axle Lubricating Oil
Sulphur-phosphorus type heavy duty (GL-5) gear oil is recommended for rear axle. The user may select
gear oil of GL-5 or above with different viscosity grades according to the local atmospheric temperature.
Designated Product

(Dongfeng
dedicated oil)
Grease
It's recommended to use universal vehicle lithium base grease as the grease for the wheel hub and
each lubricating point.
Designated Product

(Dongfeng
dedicated oil)
98 D530.KD5K.H1008
Clutch Booster Fluid
Designated Product Dongfeng Dongfeng Motor Vehicle Oil Co., Ltd.
Dongfeng Motor Co. Ltd. Lubricating Oil

Co., Ltd.
Recommended product Castrol Dongfeng Lubricants Co., Ltd.

Tongli
Shell Tongyi (Xiangfan) Petroleum Chemical
Co., Ltd
Engine Coolant
Dongfeng Cummins Engine Company requires to use mixture of deicing fluid (glycol) and pure water as
engine coolant, with DCA4 additive mixed in proportion. The ratio of deicing fluid to pure water should
be within 40-68%. The recommended DCA4 concentration is 0.5 unit DCA4 per litre deicing fluid.
Designated Product Dongfeng Dongfeng Motor Vehicle Oil Co., Ltd.
Dongfeng Motor Co. Ltd. Lubricating Oil Co.,

Ltd.
Recommended product Castrol Dongfeng Lubricants Co., Ltd.

Tongli
Shell Tongyi (Xiangfan) Petroleum Chemical Co., Ltd
Warning:
1. Freezing point of anti-freeze fluid used in especially cold area should be 10℃ lo w er
than local minimum environmental temperature.
2. Do not mix various types of anti-freeze and anti-rust fluids.
D530.KD5K.H1008 99
Technical Parameters
Mass Parameters
Mass Parameters (kg) DFL1160-999 chassis
Loading mass 10,480
Kerb weight 5,950

Zero
Front axle load 3,090
load
Rear axle load 2,860
Allowable front axle load 6,300
Full load Allowable rear axle load 11,600
Allowable total mass 17,900
Dimension Parameters
Dimension Parameters (mm) DFL1160-999 chassis
Total length 8,750
Total width 2,464
Total height 2,846
Wheelbase 5,000
Length ——
Internal dimensions
Width ——
of carriage
Height ——
Wheel base Front axle 1,920
Rear axle 1,860
Length of suspension Front

1,480
suspension
Rear
2,320
suspension
Approach angle (°) 23
Departure angle (°) 10
Ground clearance 327
100 D530.KD5K.H1008
Performance Parameters
Performance Parameters DFL1160-999 chassis
Maximum speed 110km/h
Maximum gradability 30%
Parking slope 20%
Minimum turning diameter 19m
Caution:
1. Kerb weight of vehicle includes lubricating oil, coolant, fuel, spare tyre and driver's tools.
2. Full load total mass of vehicle includes the mass of 3 persons in the cab (195kg).
3. Minimum turning diameter of vehicle is measured from the center of front external wheel
mark.
4. The front wheel base is measured from the front wheel ground contact center and the rear
wheel base is measured from the twin tyres center.
5. The minimum ground clearance is the ground clearance of rear axle under full load.
6. The total height is measured under zero load from the cab roof.
7. The maximum gradability is the ability of single vehicle under full load to pass through the
grade.
8. For the newly purchased chassis (incomplete vehicle), the suspension does not present
pre-deformation and the (intermediate) rear axle load does not reach the normal use value
before carriage refit. To protect the vehicle, it's recommended that the maximum running
speed should not be more than 60km/h; otherwise, it will aggravate vehicle vibration and
impact the service life of parts.
D530.KD5K.H1008 101
Assembly Structure
Assembly Structure
Engine
Manufacturer Dongfeng Cummins Engine Co., Ltd.
Pattern Water cooling, in line, 6-cylinder, supercharged intercooling diesel

engine
Fuel supply mode High pressure common rail injection pump
Model ISDe270 30
Rated power (kW/r/min) 198/2,500
Maximum torque (N·m/r/min) 970/1,400
Cylinder bore × stroke (mm × mm) 107 × 124
Displacement (L) 6.7
Compression ratio 17.3:1
Ignition sequence 1-5-3-6-2-4
Fuel: summer: #0 light diesel oil; winter: appropriate light diesel oil suitable for air temperature.
Clutch
The clutch is of single plate dry type diaphragm spring type clutch. The outside diameter of friction lining
is ø430mm. It adopts hydraulic remote control. The clutch pedal free stroke is 10mm-20mm.
Transmission
It is equipped with DC7J120TD mechanical 7-gear transmission, adopting remote flexible shaft control.
The transmission speed ratio is as follows:
Reverse
1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear 7th gear
gear
10.307 6.811 4.462 2.807 2.008 1.375 1.00 10.144
Driving Shaft
The driving shaft is open type, cross axle type universal joint with cross axle needle bearing.
102 D530.KD5K.H1008
Assembly Structure
Front Axle
Forging steel part, end elliott type I-beam structure, steering axle.
Front wheel camber 1°

Front wheel alignment
Kingpin inclination angle 7°
angle
Castor angle 2°30 ′
Maximum turn angle of Interior wheel 43°

front wheel
Exterior wheel 34°
Rear Axle
Driving rear axle, single stage hyperboloidal gear final drive, full floating type half axle. The main
reduction ratio is 4.44.
Wheel and Tyre
Every vehicle is equipped with 7 tyre assemblies, one of which is spare tyre. It's recommended to adopt
longitudinal dual purpose pattern. Rim pattern: 8.25 × 22.5.
Tyre specification: 11.00R22.5.
Suspension
Both front and rear plate springs (main and auxiliary) are of multiple leaf springs. Both front suspension
and rear suspension adopt lifting eye structure. The front suspension is provided with dual direction
acting damper. The front spring consists of 9 leaves and the rear spring consists of 10+8 leaves.
Frame
Stamping riveted structure. The maximum cross section dimensions of longitudinal beam are: 280mm ×
80mm × 7mm. The longitudinal beam intermediate section is equipped with stiffening plate inside and
the exterior width of frame is 860mm. The primary cross beam is equipped with towing hook at the
center.
Steering System
The steering system is of power steering system, adopting dual spoke type steering wheel, integral
power steering gear and vane type steering hydraulic pump. The transmission ratio of steering gear
middle position is 18.72.
Brake System
Main equipment: water cooling single cylinder type air compressor, air vessel (three 30L air vessels)
and one air processing unit.
Valves (quick release valve, four-circuit protection valve, water drain valve, air inflation valve, brake
valve, load sensing valve, manual valve, exhaust brake valve, differential valve etc.), combined type
drier and brake hose etc.
Service brake: using double-circuit, suspension type brake valve and drum type wheel brake.
D530.KD5K.H1008 103
Assembly Structure
Parking brake: manual valve controlled spring brake air chamber, acting on intermediate/rear axle
brake and controlling the trailer brake through trailer control valve.
Auxiliary brake: electric-air controlled butterfly valve, engine exhaust brake.
Electrical System
Adopt 24V circuit system, negative ground. Main electric appliances and instrument parameters:
speedometer, tachometer, water thermometer, fuel gauge, manometer (2).
Battery 12V, 100A.h(2)
Generator 28V, 70A
Starter 24V, 6kW
Lamps: front combination lamp, front fog lamp, rear combination lamp, side turn lamp, steering foot
lamp, outline marker lamp, marker lamp, side marker lamp, step lamp, fluorescent lamp, cab roof lamp,
reading lamp, service lamp and reflector.
Indication and warning: turn signal lamp, charge indicator lamp, parking indicator lamp, exhaust brake
indicator lamp, water temperature overheating and low level alarm, low air pressure alarm and warning
lamp, low oil pressure warning lamp, air drier heating indicator lamp, electric horn, air horn, warning
indicator lamp, stop check indicator lamp and start wait indicator lamp.
Cab
The flat roof cab is of tiltable cab-over-engine type, adopting hydraulic tilting mechanism. It has a two-
stage boarding step. The front row seats inside the cab include driver's seat, center seat (or center
glove box) and passenger's seat. The driver's seat is standard spring shock-absorbing seat, backrest
angle of which allows front and back adjustment. Airbag shock-absorbing seat is optional. The
passenger's seat also allows front and back adjustment of backrest angle. The rear row seat is provided
with berth of 2,025mm × 550mm. The cab is also equipped with heat insulation carpet, glove box,
electronic clock, cigarette lighter, radio & cassette player, interior rearview mirror, sun visor and curtain
rail. Both doors can be equipped with lock, the door glass can be raised and lowered while the rear
side window glass cannot open. It's equipped with tiltable faceshield and metal bumper. The front
windshield is equipped with power wiper and washer, the door is equipped with exterior rearview mirror
and front ground mirror.
Heater and A/C
The cab is provided heater inside, A/C for optional. The cab refrigeration system employs
environmental protection freon-free A/C system and uses R134a as refrigerant.
Carriage
The truck carriage is of iron and wood composite construction.
Driver's tool
Each commercial vehicle is equipped with one set of driver's tools.
104 D530.KD5K.H1008
Schematic Diagram of Brake
Schematic Diagram of Brake
1. Air compressor 9. Manual valve

2. Air processing unit 10. Front air vessel
3. Brake valve 11. Rear air vessel
4. Quick release valve 12. Auxiliary air vessel
5. Front air chamber 13. Joint group
6. Load sensing valve 14. Differential valve
7. Spring air chamber, 11-port
8. Spring air chamber, 12-port
Electrical Schematic Diagram

The electrical schematic diagram attached in this manual is the general electrical schematic diagram.
Refer to the specific configuration when using it.
D530.KD5K.H1008 105

DFL1160 999系列 (KD5K) 使用手册 EN

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DFL1160 999系列 (KD5K) 使用手册 EN

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Dongfeng DFL1160-999 Motor Chassis

DONGFENG MOTOR CO., LTD.

Models the manual applicable are: DFL1160-999

DONGFENG MOTOR CO., LTD.

3. No regular maintenance (including running-in maintenance and mileage maintenance) is executed

10. The vehicle is operated overloaded or ultra limited.

15. Vehicles that are no more in quality warrant period.

All rights reserved.

Location of the Model Nameplate ................. 1 Warning Triangle ......................................... 49

Location of VIN.............................................. 1 Diagnostic Fault Code ................................ 50

Location of the Engine Nameplate................ 1 Levers ......................................................... 51

Location of Fuel Injection Pump Nameplate . 2 Check of Drier ............................................. 52

Location of ECM Nameplate ......................... 2 Methods to Release Spring Brake .............. 53

Daily Inspection ............................................. 3 Rear Guard Rail .......................................... 53

Running-in of New Vehicle ............................ 4 Start and Drive .................................................. 54

Standard Operation ....................................... 5 Engine Start ................................................ 54

Structure and Operation .................................. 10 Clutch Operation ......................................... 56

Instruments and Control Mechanism .......... 10 Brake Operation.......................................... 57

Keys ............................................................ 11 Parking ........................................................ 57

Doors ........................................................... 11 Slope Driving Method ................................. 57

Seat ............................................................. 12 Maintenance and Adjustment ......................... 58

Passenger's Seat ........................................ 13 Checking and Adding Coolant .................... 58

Maintenance and Adjustment Data................. 91 Brake System ........................................... 103

Engine Section ............................................ 91 Electrical System ...................................... 104

Chassis Section .......................................... 92 Cab............................................................ 104

Tightening Torque........................................ 93 Heater and A/C ......................................... 104

Bulb ............................................................. 96 Carriage .................................................... 104

Capacity Data .............................................. 97 Driver's tool ............................................... 104

Oil and Grease ............................................ 97 Schematic Diagram of Brake ........................ 105

Technical Parameters .................................... 100 Electrical Schematic Diagram ...................... 105

VIN means vehicle identification number, printed

Location of the Engine Nameplate

Engine nameplate provides the exclusive data of

Location of Fuel Injection Pump Nameplate

The nameplate of Bosch fuel pump is on the top of

Location of ECM Nameplate

ECU is in the instrument board in the cab.

Electronic control module (ECM) nameplate

ECM nameplate provides the following

ECM part number (PN);

ECM production serial number (SN);

ECM date code (DC);

Engine production serial number (ESN);

ECM code: indicating the software in ECM

Please check carefully the vehicle before driving.

1. Check the coolant level (see Page 69).

2. Check the lubricant level of the engine (see Page 72).

4. Check the fuel filter (see Page 74)

5. Check the drainage of oil water separator (see Page 74).

6. Check the power steering oil level.

7. Check the fuel tank level (see Page 63).

8. Check the tyre pressure and tyre tread.

9. Drain water from the air vessel.

10. Check and clean the glass and rearview mirror.

11. Check the clutch hydraulic oil level.

12. Check the horn.

13. Check the light.

16. Check the fan belt and fan for damage.

22. Check the engine oil in time in the event of emulsification.

27. Check the clutch pedal free stroke.

28. Check the brake pedal free stroke.

31. Check the exhaust pipes for deformation and leak.

33. Check whether engine throttle response is sensitive.