DFL1120B

DFL1120B
DFL1120B1
Dongfeng Vehicle Chassis
DFL1120B2
DFL5120XXYB1
User’s Manual
DONGFENG MOTOR CO., LTD.

May 2013
D530EGR.KD1E-KD3E.KF1E-KF4E.H1305
Foreword
Thanks for purchasing and using Dongfeng motor vehicles. We sincerely hope they will bring you infinite
wealth.
It is our common objective to optimize your vehicle, which, however, to a great extent, depends on your
familiarity with the vehicle and the careful and comprehensive maintenance. You are appreciated to go
through this manual and thus to get familiar with operation procedures therein before you operate the
vehicle.
As an integral part of the vehicle, this manual should be kept and used with the vehicle. It shall be noted
that, to meet users' demands, Dongfeng Motor Co., Ltd. will constantly improve and perfect the vehicle
products. The company shall reserve the right to modify the product design and technical features at any
time. Therefore, the figures and description in this manual are correct upon publication, and no further
notice will be made upon the subsequent modification. The parameters concerning the bulletin shall
refer to the national bulletin. Thanks for your understanding.
This manual is applicable for DFL1120B, DFL1120B1, DFL1120B2 and DFL5120XXYB1 series vehicle
chassis. When reading this manual, please refer to the specific configurations of your vehicle. These
series have all reached China III emission standard.
For problems related to warranty and genuine component purchase of our products, please contact the
Technical Service Centre (Station) or Customer Service Centre of Dongfeng Commercial Vehicle
Company. Sunshine Service Hotline: 0719-8885555 or Free Call: 800-880-5800.
DONGFENG MOTOR CO., LTD.

May 2013
Use of Manual
This manual describes the structure & operation, starting & driving, maintenance & adjustment, as well
as technical parameters and service & adjustment data for Dongfeng vehicle products. The user should
perform the inspection and maintenance work in strict accordance with the maintenance interval mileage
specified in the regular maintenance schedule.
Symbols in the manual are specified as follows:
WARNING: Failure to observe the requirement with a warning mark will result in serious
personal injury or property loss.
CAUTION: Failure to observe the requirement with a caution mark will result in personal
injury or damage to component assembly or complete vehicle.
Declaration
DONGFENG MOTOR CO., LTD. shall be relieved of the responsibility for products’ reliability, safety or
compatibility in case of one of the followings:
1. The nameplate and the certificate of the complete vehicle or chassis issued by our company do not
match the material object, or are altered.
2. Failure to observe the requirements in this manual to properly use and operate the vehicle.
3. No regular maintenance (including running-in maintenance and mileage maintenance) is executed
at service station in accordance with this manual.
4. Failure to use the oil products, coolant, air filter elements, fuel filter elements and oil filter elements
designated in this manual.
5. The customer repairs the vehicle when it is faulty within the quality guarantee period instead of
getting it repaired in the Technical Service Station authorized by Dongfeng Commercial Vehicle
Company of Dongfeng Motor Co., Ltd.
6. Malfunction caused by altering the original structure of the vehicle without authorization of our
company, such as retrofitting, addition or parts modification, namely, room extending, frame
strengthening, leaf spring thickening, or tyres layering or widening.
7. Malfunction caused by the failure to use the genuine parts recognized by our company when
repairing the vehicle.
8. Deteriorated successive fault and related components damage caused by continuously driving the
vehicle with fault or potential fault which is not eliminated in time.
9. The customer handles the traffic accident privately without the duty confirmation executed by
involved parties such as public security traffic administrative authority and insurance company.
10. The vehicle is operated beyond the load limit or other limits.
11. Impact, burning damage, scratching or chipping caused by external factor rather than the internal
fault of the products.
12. Vehicle damage caused by force majeure, such as flood, lightning, storm and hailstone.
13. Normal deterioration of the vehicle like noise, vibration, wear 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 guarantee period.
16. Other repairs not associated with material, design or manufacturing, unauthorized changes or
modifications to vehicle design without approval.
All rights reserved
Contents
Comprehensive alarm ................................... 54
Vehicle Identification .................................... 1
Multifunction buzzer ...................................... 54
Location of Vehicle Nameplate........................ 1
Central Distribution Box ................................. 55
Location of VIN ............................................... 1
Adjustment of Steering Wheel ....................... 57
Location of Engine Nameplate and
Ex-factory Code .............................................. 1 Towing Hook ................................................. 58
Precautions ..................................................... 2 Front face shield ............................................ 58
Environment-friendly Operation and Fire Extinguisher ........................................... 59
Adjustment of Engine ...................................... 2
Cab Tilting ..................................................... 60
Daily Inspection .............................................. 3
Adding of Fuel ............................................... 61
Running-in of New Vehicle .............................. 4
Warning Triangle ........................................... 61
Standard Operation......................................... 5
Rear Protection ........................................... 62
Safety Precautions .......................................... 7
Basic Requirements for Truck Side and
Precautions for Load Sensing Valve ............. 10 Rear Protection ............................................. 62
Structure and Operation ............................. 11 Basic Requirements for Engineering
Vehicle Side and Rear Protection .................. 69
Arrangement of Instrument and Control
Mechanism ................................................... 11 Starting & Driving ........................................ 75
Keys.............................................................. 12 Engine Start (Cummins B Series Engine) ...... 75
Doors ............................................................ 12 Clutch Operation ........................................... 77
Central Locking ............................................. 13 Transmission Operation ................................ 79
Seats ............................................................ 13 Braking Operation ......................................... 80
Seat Belts ..................................................... 16 Operation of Governor Diagnostic Switch
(Option) ......................................................... 81
Berth ............................................................. 17
Parking operation .......................................... 81
Instrument Cluster......................................... 18
Parking .......................................................... 82
Indicator lamp and alarm lamp ...................... 22
Slope Driving Method .................................... 82
Master power switch ..................................... 28
Maintenance & Adjustment ........................ 83
Rocker Switch ............................................... 28
Inspection and Adding of Coolant .................. 83
Combination Switch (without cruise control) .. 31
Drainage of Coolant ...................................... 84
Key switch..................................................... 35
Maintenance of Air Filter ............................... 84
Ventilations ................................................... 36
Drainage of Fuel Tank ................................... 85
Climate Control System ................................ 38
Maintenance of Cummins B Series Engine ... 86
Gear Lever .................................................... 42
Oil filter .......................................................... 88
Manual valve control lever ............................ 42
Fuel Primary Filter ......................................... 89
Methods to Release Spring Brake ................. 43
Piston type spring brake air chamber ............ 44
Accessory System ........................................ 45
Glove Box ..................................................... 47
Radio & CD player ........................................ 49
Tachograph................................................... 53
Fuel filter & oil mist separator ........................ 90 Grease Filling Mileage Schedule ................. 139
Bleeding of Fuel System ............................... 91 Service and Adjustment Data ................... 140
Maintenance of by-pass supercharger .......... 91 Engine ......................................................... 140
Inspection & adjustment of advance angle for Chassis ....................................................... 140
fuel supply..................................................... 92
Tightening Torque ....................................... 142
Inspection of injector ..................................... 92
Bulb ............................................................. 150
Inspection of Clutch Fluid Level .................... 92
Capacity Data.............................................. 151
Adjustment of Clutch ..................................... 93
Oil Products and Grease ............................. 153
Bleeding of Clutch ......................................... 93
Technical Parameters ............................... 157
Maintenance & Adjustment of Brake ............. 95
Mass parameters ........................................ 157
Automatic Adjuster ........................................ 96
Dimension Parameters ................................ 158
Disk brake ..................................................... 97
Performance Parameters ............................ 160
Inspection of Brake Pedal Travel ................ 105
Assembly Structure .................................. 163
Inspection of air dryer ................................. 106
Engine ......................................................... 163
Inspection and Change of Power Steering
Clutch .......................................................... 163
Hydraulic Oil ............................................... 107
Transmission ............................................... 163
Inspection of Steering Wheel Free Turn ...... 108
Propeller Shaft ............................................ 163
Inspection of Driving Axle Final Drive Oil
Level ........................................................... 109 Front axle .................................................... 164
Tyre Use and Maintenance ......................... 110 Driving axle ................................................. 164
Tyre Transposition ...................................... 113 Wheel and Tyre ........................................... 164
Adjustment of Front Wheel Alignment ......... 115 Vehicle frame .............................................. 164
Tyre Inflater................................................. 115 Suspension ................................................. 164
Maintenance of Wheel Hub Bearing ............ 116 Steering System .......................................... 164
Removal and Installation of Spare Wheel ... 118 Brake System .............................................. 165
Replacement of tyre .................................... 118 Electrical System ......................................... 165
Inspection and Maintenance of Battery ....... 119 Cab ............................................................. 166
Fusible link .................................................. 120 Heater and A/C ........................................... 166
Arrangement of Lamplight ........................... 121 Carriage ...................................................... 166
Light Adjusting Method ............................... 123 Driver’s Tool ................................................ 166
Auxiliary Power Starting .............................. 125 Schematic Diagram of Brake .................... 167
Maintenance of Cab Lifting Device .............. 126 Diagnostic Fault Code List of Speed
Governor (Optional) .................................. 168
Regular Maintenance Schedule ............... 131
Electrical Schematic Diagram .................. 168
Inspection and Maintenance Term .............. 131
Regular Renewal Part ................................. 138
Vehicle Identification
Location of Vehicle Nameplate
The vehicle nameplate is placed inside the right
door of the cab.
1. Vehicle nameplate
Location of VIN
VIN means vehicle identification number, which is
printed on a conspicuous location on the right side
sill of the frame.
Location of Engine Nameplate and

Ex-factory Code
For Cummins B series engines
1. Location of engine nameplate

2. Location of ex-factory code
D530EGR.KD1E-KD3E.KF1E-KF4E.H1305 1
Precautions
Environment-friendly Operation and Adjustment of Engine
1. DONGFENG MOTOR CO., LTD. shall regard any private or unauthorized removal of lead seals of
the engine as automatic abandonment of the warranty.
2. The engine has been strictly adjusted before delivery and met the requirement of the national
environmental laws. The user is not allowed to execute unauthorized alternation or adjustment. The
engine can only be adjusted in the service station designated by Dongfeng Commercial Vehicle
Company of Dongfeng Motor Co., Ltd. Dongfeng Motor Co., Ltd. shall regard any private altering or
adjustment in any unauthorized service station as automatic abandonment of the warranty.
3. Use the oil filter element and fuel filter element designated by the engine manufacturer.
4. Strictly observe the following during the operation and maintenance:
a. Perform regular maintenance and replacement of the oil filter, the fuel filter and the air filter.
b. Make sure to apply the designated or recommended model and specification of oil, and change
the oil regularly.
c. Add high quality diesel of different grades under different climate conditions; do not use
poor-quality diesel.
d. Always check the level of coolant and lubricating oil regularly, and add if necessary.
e. Check that the connecting pipes for supercharger, intercooler and intake & exhaust pipes are
airproof.
f. Before driving, let the engine run idly for 3-5 min to lubricate sufficiently all its parts, especially
the supercharger in order to ensure the normal operation of the supercharged engine. After
starting the engine, never warm up it by means of acceleration. Before shutdown, let the
engine run idly for 3-5 min, to cool down normally all its parts, especially the turbine casing of
the supercharger, in order to prevent the gumming or carbon deposition of the lubricating oil on
the hot component, which will lead to malfunctions like blockage.
2 D530EGR.KD1E-KD3E.KF1E-KF4E.H1305
Daily Inspection
Please check carefully the vehicle before driving.
1. Check the coolant level (see Page 83).
2. Check the engine lubricating oil level (see Page 86).
3. Check the fuel level in the fuel tank (see Page 19).
4. Check the wheel nut for looseness, and check the tyre pressure and tread (see Page 112).
5. Check for any leakage of fuel, oil, water or air.
6. Check and clean the glass and rear-view mirrors.
7. Check the clutch hydraulic fluid level (see Page 92).
8. Check the horn (see Page 31).
9. Check the light (see Page 32).
10. Check the condition of steering wheel, transmission control lever and brake.
11. Check the free stroke of the brake pedal (see Page 105).
12. Check the stroke of wear indicator of disc brake.
CAUTION:
1. Draining of water separator of fuel primary filter (see Page 85)
a. Drain it every week or drain the water and deposits when the water-in-fuel
indicator lamp is on (applicable for the model with water-in-fuel indication
function);
b. For refueling, it is recommended to drain the water and deposits in the water
separator of fuel primary filter after the shutdown each day.
2. Check the draining of the air reservoir once every week, or after the shutdown each
day in winter and cold area (see Page 106).
3. When the wear indicator of friction plate indicates that the friction plate is at the
wear limit, the friction pad assembly must be replaced.
Running-in of New Vehicle

The running-in mileage is 1,500-2,500 km, and the following should be noticed during the running-in:
1. Loading is strictly prohibited in the first 250 km of running-in. The engine speed can never exceed
2,000 r/min.
2. The load shall not exceed 75% of the nominal load capacity in the running-in period after 250 km.
3. Drive the vehicle on a level and hard road with minor slope throughout the running-in period.
4. Run the engine under a proper light load or idly for a while to warm it up after starting it.
5. Never run the engine at an idle speed for a long time. Before the operation under a load, the idling
time cannot exceed 5 min; otherwise, the engine will be damaged (except the operation under a
load in case of an optional full-power PTO).
6. Never drive the vehicle at a constant speed for a long time.
7. Properly use the transmission gears to avoid overloading the engine.
8. Often note the indication of the engine oil pressure (check low oil pressure alarm lamp) and the
coolant temperature.
9. Check frequently the engine lubricating oil level and coolant level.
10. For the vehicle employing flexible cowl in cooling system, check the flexible cowl hoop for
looseness and re-tighten it if necessary.
11. Drive the vehicle properly, avoid abrupt braking, and properly use engine exhaust brake or other
auxiliary brakes.
12. Never shut down the engine abruptly after it has been running at high speed or under heavy load for
a long time. Keep the engine running idly after driving, and shut it down after it is cooled.
13. Check whether the wheel nuts are loose after running-in, and if so, torque tighten the nuts to
550-650 N·m.
CAUTION:
After running-in of the new vehicle, please perform running-in maintenance in the
nearest technical service centre (station) authorized by Dongfeng Commercial Vehicle
Company of Dongfeng Motor Co., Ltd. in accordance with the rules of Dongfeng
Commercial Vehicle Quality Assurance Manual.
Standard Operation
In order to prolong the service life, gain higher economic benefit, and guarantee the travel safety, the
following should be noticed during the vehicle operation:
1. When operating the vehicle, turn on the master power switch, and then make sure that the
transmission control lever is at neutral position in the low range.
2. Engine start operation (see Page 75).
3. Do not increase the engine speed too fast if the engine temperature is low; otherwise the wear of
engine moving parts will be aggravated.
4. Never move the vehicle before the brake system pressure reaches and exceeds the stipulated
pressure (the barometer pointer not in the red zone) when the parking brake indicator lamp is off.
5. The vehicle under heavy load must be started at first gear.
6. It is strictly prohibited to coast the vehicle at neutral gear with engine stalled.
7. 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.
8. Avoid sharp turn at high speed.
9. Never overload the vehicle since it may shorten its service life.
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 accordance with the User’s Manual, and the nominal load capacity and
gross mass specified in the manual shall never be exceeded. Overload may result in
vehicle malfunction and damage and even personal injury.
10. When cleaning the vehicle, avoid the entry of water into the oil tank.
11. Never turn off the master power switch when the engine is running; make sure to turn off the switch
after the vehicle enters into the yard and stops.
12. Before tilting the cab, make sure to check for any object that is easy to get upside down inside the
cab. And remove such objects if any.
13. When maintaining or adjusting the electrical system, the main power must be switched off before
the replacement of the electric elements. Never perform any operation with power on.
14. Never replace the fuse or fusible link with copper wire. Do use the stipulated fuse.
15. Never check the electrical system by testing the live wire through short circuit.
16. The assembly must be resumed after the electric elements are removed and replaced.
17. Protect the electronic control unit of the vehicle as follows before performing welding on the vehicle:
For the vehicle equipped with electromagnetic master power switch:
Output Output
Control terminal
Control terminal
Electromagnetic master
Grounded
power switch
Grounded
Input Input
Vehicle
Vehicle frame
frame
Initial state State before welding
Specific operation steps:

a. Disconnect the positive wire from the output terminal of electromagnetic master power switch.
b. Have the positive wires of input and output terminals of the electromagnetic main power switch
short circuited.
c. Disconnect the positive and negative cables of the battery.
d. Connect the positive cable to the negative one, and then connect them to the frame.
WARNING:
1. Prevent power short circuit while disconnecting and connecting the power cable.
2. Restore all wirings after the welding.
3. Failure to perform welding in this way may result in irremediable defect of vehicle
electronic devices.
Safety Precautions
WARNING: Failure to observe the requirement with a warning mark will result in serious
personal 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 accordance with the
User’s Manual, and the nominal load capacity and gross mass specified in the manual shall never
be exceeded. Overload may result in vehicle malfunction and damage and even personal injury.
2. Make sure to observe the operation specifications to protect vehicle electronic equipment during
welding; otherwise irremediable defect will be caused to vehicle electronic devices (see Page 5).
3. The seat belt can be used by one person only. Adult and kid are prohibited to share one belt. The
whole belt should be replaced if the seizure of seat belt retractor occurs or any component comes
into failure or damage. Make sure that the belt is not intertwined, clear of hard edges and free from
chemical pollution. And always adjust the belt length according to the body; otherwise hazard will be
caused.
4. When parking vehicle, be sure to move the manual valve control lever to locking position; otherwise,
the vehicle may move, which will lead to damage or even personal injury. The spring brake can only
be released in emergency. After that, the fault must be eliminated and the parking brake shall be
restored. The vehicle without parking brake is dangerous, and it may result in an accident (see
Page 44).
5. Adjusting the position of the steering wheel is strictly prohibited during driving.
6. Always shut down the engine and park the vehicle on a level ground before tilting the cab. Check for
sufficient space when tilting the cab inside. Check that the parking brake control lever is at locking
position and the transmission control lever is at neutral position, and chock the tyres. Put away the
scattered objects inside the cab and those which are easy to fall during cab tilting. The cab must be
tilted to proper position, with the centre of gravity tilting over the support point to avoid the cab to
slide accidentally. Do not move the reversing handle after cab tilting. It must be in proper position
when the cab lowers to the original place (see Page 60 for cab tilting).
7. Do not move the transmission control lever while the engine is running after cab tilting, nor lower the
cab with engine running. (See page 76)
8. Never connect the cigar lighter for a long period. It must be drawn out manually if it fails to pop out
automatically.
9. The filler cap can be removed only after the coolant temperature is below 50°C, otherwise, the hot
coolant or the steam will sprinkle, causing serious personal injury. Before removing the coolant filter,
please remove the filler cap of auxiliary water tank and close the shutoff valve; otherwise, hot
coolant may sprinkle to cause personal injury.
10. Never replace the fusible link (fuse) with ordinary conducting wire or fusible link of other
specifications.
11. Make sure to use only the oils and greases stipulated in this manual; otherwise vehicle malfunction,
damage and even personal injury may occur.
12. If the alarm lamp stays on or flashes when the engine is running (see Page 22 for indicator lamp
and alarm lamp), then it indicates that some part is in trouble. In this case, please contact the
Technical Service Center (Station) authorized by Dongfeng Commercial Vehicle Company of
Dongfeng Motor Co., Ltd. as soon as possible.
13. Original spare parts should be used for friction pad and brake disc, otherwise, serious consequence
will occur.
14. When replacing tyres by yourself, be sure to install tyre valve clip properly, otherwise interference
may occur between tyre valve and brake, causing tyre burst and even personal injury and property
loss.
15. Never extend the head and hand outside the window when the power window is rising. In this
course, if the body or other objects are nipped between the glass and door frame, always move the
glass downward immediately. When operating the passenger's power window regulator switch, the
driver shall ensure that there is no obstacle affecting the correct closing of the window, and that the
passenger can use the regulator switch correctly.
16. No corrosive or hard object, or object with sharp edge and corner is allowed in the glove box. And
no heavy load is allowed on the glove box cover.
CAUTION: Failure to observe the requirement with a caution mark will result in personal
injury or damage to component assembly or complete vehicle.
1. Observe the vehicle operation specifications strictly (see Page 5).
2. Check that all doors are closed properly before starting the vehicle. Always lock the door only with a
key when you are outside the vehicle; never lock the door by moving the lock knob forwards while
pressing the outside unlocking button to close the door.
3. The master power switch shall never be turned off when the engine is running. Never turn the key to
START position when the engine is running to avoid damaging the starter.
4. Never use the washer without washer fluid.
5. When the A/C compressor needs to be restarted after being shut off, please wait for 3-5 min;
otherwise, the service life of the compressor will be affected.
6. For the sake of safety, do close the ash tray before leaving the vehicle.
7. When getting power via the working lamp socket, the electrical load is strictly prohibited to exceed
the nominal capacity of the socket.
8. Before adding coolant, always check the engine and the radiator for leakage, and repair it if any.
Long-life antirust and anti-freeze coolant should be used. Never use tap water or hard water from
the well or river.
9. Normally do not screw off the pressure valve cap of the auxiliary water tank; if it is necessary to do
so, be careful to avoid scalding.
10. Check the engine oil level only when the vehicle stops. Make sure to drain the lubricating oil off after
the engine completely stops. Be careful not to be scalded by hot oil during the oil draining.
11. When mounting the air filter, make sure to mount the filter element and end cover properly;
otherwise dirt may be absorbed, sharply shortening the engine service life. Never clean the filter
element with gasoline or water. Check the sealing rings during installation. Tighten the filter element
and end cover nut, and install the sealing ring of the end cover properly. Do not remove the air filter
when the vehicle is running.
12. Do not tighten the fuel primary filter and fuel filter with filter spanner during the installation.
Otherwise the threads may deform and the filter may be damaged. When mounting a new filter,
please check whether it is compatible with the engine. Before installing the oil filter, the filter should
be filled with oil.
13. No exhausting operation is allowed when the engine temperature is high. The starting time of the
engine must not exceed 30 s, and the interval between starting operations shall be 2 min at least.
14. For the manual adjuster, check the brake clearance regularly and adjust it in time if the braking is
weak. During the adjustment of brake clearance, never change the push rod stroke by screwing the
connecting yoke of the brake air chamber push rod. To adjust the rear brake, always park the
vehicle on a flat place and ensure the air reservoir pressure is above 700 kPa. Then chock the
wheels at the front and back, and release the parking brake before adjusting the rear brake
clearance.
15. For the automatic adjuster, never adjust the brake clearance manually except for extraordinary
circumstances. Check the wear condition of friction plate to prevent braking failure due to overworn
friction plate. When manual adjustment of brake clearance is necessary, never change the push rod
stroke by screwing the connecting yoke of the brake air chamber push rod. Before adjusting the rear
brake manually, make sure to park the vehicle on a level place and ensure the air reservoir
pressure is above 700 kPa. Then Chock the wheels at the front and back, and after releasing the
parking brake, adjust the rear brake clearance. In case the braking is abnormal, make sure to stop
the vehicle immediately to check the automatic adjuster and other components of the brake system,
and take necessary measures to eliminate the fault (see Page 96).
16. Disc brake can adjust its clearance automatically, so manual adjustment of brake clearance is
prohibited unless in extraordinary circumstance. In the case of abnormal brake clearance, check the
clearance adjustment mechanism (see Page 98).
17. Check the friction plate for wear regularly to avoid brake failure due to excessive wear of friction
plate.
18. Never adjust the pressure of brake air line privately to avoid damaging the parts.
19. Never add power steering fluid with engine running.
20. Normally, the battery should be removed for charging when it is discharged. Starting by auxiliary
power can be allowed only in emergency, and should be carried out in strict accordance with the
operation specifications.
21. Never let the steering wheel stay at the limit position for more than 15 s. In such a case, it is
required to slightly rotate the steering wheel backwards so as to prevent any damage to the power
steering pump.
22. When performing the specified maintenance to the vehicle, the user should shorten the
maintenance interval mileage according to the actual operation condition, to ensure more
reasonable maintenance and higher reliability of the vehicle. However, the user should never
prolong the maintenance interval mileage (see Page 132).
Precautions for Load Sensing Valve
Please refer to the specific configurations of your

vehicle.
The load sensing valve is usually located near the
back-end of the frame side member and the rear
axle. The load sensing valve is used to adjust the
braking force of the rear axle by the oscillating bars
of different angles, to ensure braking stability of the
vehicle under different loads. In addition, the load
sensing valve has relay valve function, which
allows for quick inflation of brake air chamber.
During the maintenance, servicing or retrofitting of
the vehicle, it is not allowed to modify the position
of the load sensing valve and the location and 1. Frame 4. Cable
angle of the related regulating mechanism 2. Load sensing 5. Bracket
(including oscillating bar, cable and mounting valve
bracket), so as not to affect the braking effect and
driving safety of the vehicle. 3. Oscillating bar
Structure and Operation

Arrangement of Instrument and Control Mechanism
1. Air vent at driver’s side (see Page 40) 9. Brake pedal

2. Instrument cluster and control panel 10. Combination switch right handle (incl. exhaust
brake switch, windshield wiper and washer
3. Air vent at passenger’s side
switches) (see Page 34) (see Page 33)
4. Radio & tape player
11. Combination switch left handle (incl. horn
5. HVAC controller switch, position lamp switch, high beam and
low beam switch, and dimmer switch) (see
6. Cigar lighter (see Page 45 )
Page 31)
7. Transmission control lever (see Page 42)
12. Clutch pedal
8. Accelerator pedal
Keys
Keys are used to control the starter switch of the
vehicle, and to lock and unlock the door.
Doors
From the outside
Insert the key into the lock hole and turn the key
towards the position "3" (the head of the vehicle) to
unlock the door; contrarily, the door will be locked;
after the door is unlocked, press down the door
outside unlocking button to open the door.
1. Locking position 3. Key inserting

position
2. Unlocking position
4. Outside unlocking
button
From the inside

When the door is closed, turn the lock knob
forward to locking position to lock the door;
contrarily, the door will be unlocked; then pull the
door inside handle to open the door.
CAUTION:
1. It is very dangerous to drive the
vehicle with the door ajar. Please
check if the door ajar alarm lamp
is on. 1. Door inside 3. Locking position
handle of door inside lock
2. The door can never be opened
when the vehicle runs. 2. Unlocking position
of door inside lock
3. The door must be locked only
with a key when you are outside
the vehicle; it is strictly
prohibited to lock the door by
placing the door inside lock at
locking position while pressing
down the door outside unlocking
button to close the door.
Central Locking
From the inside
When both the driver and the passenger are in the vehicle, the passenger’s door will be locked also after
the door lock knob at driver’s side is turned to locking position. If the door lock knob at passenger’s side
is turned to locking position, then only the passenger’s door instead of the driver’s door can be locked.
From the outside
When unlocking the driver’s door with a key, the passenger’s door will be also unlocked; pressing the
door outside unlocking button can open the driver’s door and passenger's door separately. If only the
passenger’s door is unlocked with a key, pressing the outside unlocking button can open the
passenger's door instead of the driver’s door.
If the driver’s door is locked with a key, the passenger's door will also be locked. If only the passenger’s
door is locked with a key, then only the passenger's door instead of the driver’s door can be locked.
Seats

vehicle.
Driver’s seat (ordinary, mechanical shock
absorbing type)
1. Turning the knob can adjust the seat in
accordance with the driver's weight, to make it
comfortable.
2. Pulling the seatback tilt adjusting lever can
adjust the inclination of the seatback, and
releasing it can lock the seatback.
3. Pulling the seatback tilt adjuster handle can
4. Press the regulating button for lowering the
head restraint with one hand and move the
restraint up and down with the other hand to
1. Weight adjusting 3. Seatback tilt
adjust its height. The restraint will be locked
knob adjuster
up when the button is released.
2. Forward and 4. Head restraint
backward
adjusting lever
Passenger’s seat (mounting frame)

2. Press the regulating button under the head
restraint with one hand and move the restraint
up and down with the other hand to adjust its
height. The restraint will be locked up when
the button is released.
1. Seatback tilt 2. Head restraint

adjuster height adjuster
Passenger's seat (mechanical shock absorbing type with slide rail)

2. Press the regulating button under the head
restraint with one hand and move the restraint
up and down with the other hand to adjust its
height. The restraint will be locked up when
the button is released.
3. Turning the knob can adjust the seat in
accordance with the passenger's weight, to
make it comfortable. Adjusting scale is
indicated on the top.
4. Pulling the slide rail adjusting lever can adjust
the fore-and-aft position of the seat, and
releasing this lever can lock the seat. When
being looked down, the handle cannot go
beyond the foremost edge of seat.
1. Seatback tilt 3. Weight adjusting
adjuster knob
2. Head restraint 4. Slide rail adjusting
height adjuster lever
Middle seat Direction for

pulling/pushing seatback
1. To use the seatback, tilt it upward to the
rearmost position, and pull it down slowly to
the bottommost position.
2. To retract the seatback, pull it up for a short
distance by both hands along the inclination
angle, and then tilt it forward to a make it
horizontal.
3. Hold the seat armrest to keep your body
stable in case of violent vibration of vehicle
body.
1. Armrest
Seat Belts
Driver’s and passenger’s seat belts

1. Pull the belt out slowly, put it between the
shoulder and the base of neck and make it
pass through the proper position of the chest.
Then insert the latch plate into the buckle until
a “click” indicating proper locking is heard.
Adjust the belt to your comfort.
2. To unfasten the seat belt, press the button on
the buckle to release the latch plate and put
the belt back slowly.
1. Buckle 2. Latch plate
WARNING:
1. Make sure that the belt is not intertwined, clear of hard edges and free from
chemical pollution.
2. The seat belt can be used by one person only. Adult and kid are prohibited to share
one belt.
3. The whole seat belt should be replaced if any component comes into failure or
damage.
4. The seat belt should be replaced if the retractor is blocked.
5. And always adjust the belt length according to the body; otherwise hazard will be
caused.
Middle seat belt

Adjust the length of the belt to your comfort in
accordance with your body conditions. Insert the
latch plate into the buckle until a “click” indicating
proper locking is heard. The passenger who is
seated in the middle seat should wear the seat belt
on the crotch rather than the waist as much as
possible.
Berth
1. When using the berth for a rest, please make

your head face to the side with head restraint.
2. By tilting the berth upwards, you can see a
glove box on both the left and right of the
underside of berth, which is used for storing
tools and carry-ons.
3. To avoid shaking of objects during driving,
use the strap in the glove box to fix the
objects.
1. Berth
2. Left and right glove boxes of berth
Instrument Cluster
Please refer to the specific configurations of your vehicle.
1. Water thermometer 8. Center/Rear axle barometer

2. Fuel gauge 9. Indicator lamp and alarm lamp
3. Trailer turn light indicator (disconnected) 10. Mileage display screen
4. Turn light indicator 11. Backlight adjusting knob
5. Speedometer 12. Trip meter reset knob
6. Engine tachometer 13. ITC malfunction indicator lamp (disconnected)
7. Front axle barometer 14. Overspeed alarm indicator lamp (optional)
Water thermometer
The water thermometer indicates the temperature

of engine coolant. It will work when the key is
turned to ON position. The sign "C" on the dial
means low temperature and "H" means high
temperature. Ideal temperature will be indicated
when the pointer is located in the middle of scales.
CAUTION:
H: 120°C 2: 80°C
When the coolant temperature is too
high, the high water temperature 1: 100°C C: 40°C
indicator lamp will be on, and then
the buzzer on the instrument panel
will sound to send an alarm. When
the coolant temperature is too high
and the vehicle continues running,
the engine will be damaged due to
overheating.
Fuel gauge
Fuel gauge indicates the fuel level in the fuel tank.
It will work when the key is turned to ON position.
On the dial, the sign "F" means fuel tank is full, and
"E" means the fuel is exhausted. When the pointer
is close to "E", refill the tank with approved clean
fuel as soon as possible.
F: Full 3: 1/4 of capacity
1: 3/4 of capacity E: Empty
2: 1/2 of capacity
Turn light indicator

This indicator is used to indicate the working
condition of the tractor turn light. Its normal
flashing means all the turn lights work normally;
fast flashing means that at least one turn light at
the same side is in trouble.
Speedometer
Speedometer indicates the running speed of the

vehicle in km/h.
Engine tachometer
The tachometer pointer indicates the engine
revolution per minute. The green zone indicates an
economic engine speed, and the red zone
indicates an overhigh engine speed.
The economic speed and warning speed of
Cummins B series engines are 1,200-1,800 r/min
and 2,500 r/min respectively.
Barometer
The barometer indicates the air pressure in the air

reservoir. Front axle barometer (with the sign “FR”)
detects the pressure of the front axle air reservoir,
and centre/rear axle barometer (with the sign “RR”)
detects the pressure of the centre/rear axle air
reservoir.
WARNING:
WARNING: Never start the vehicle
when the pointer is in the red zone.
1. Front axle barometer

2. Center/Rear axle barometer
Overspeed alarm indicator lamp (optional)

vehicle.
This indicator lamp will be on when the vehicle
speed exceeds the specified maximum speed.
Indicator lamp and alarm lamp

1. Low beam indicator lamp 16. Inter-wheel differential lock indicator lamp
(disconnected)
2. Bogie differential lock indicator lamp
(disconnected) 17. ECAS alarm lamp /ECAS failure alarm lamp
(disconnected)
3. Parking brake indicator lamp
18. Transmission high gear indicator lamp
4. Filament detection alarm lamp
(disconnected)
5. Charging indicator lamp
19. Retarder indicator lamp (disconnected)
6. Low oil pressure alarm lamp
20. Transmission low gear indicator lamp
7. High beam indicator lamp (disconnected)
8. Exhaust brake indicator lamp 21. ASR malfunction indicator lamp
(disconnected)
9. Rear fog lamp indicator lamp
22. Air filter clog alarm lamp
10. Air dryer heating indicator
23. Tractor ABS malfunction indicator lamp
11. Fuel preheating indicator lamp (disconnected)
(optional)
12. Intake air preheating indicator lamp
24. Trailer ABS malfunction indicator lamp
13. Seat belt indicator lamp (disconnected)
14. Door ajar alarm lamp 25. Low water level indicator lamp (disconnected)
15. Front fog lamp indicator lamp 26. Air suspension indicator lamp (disconnected)
27. PTO indicator lamp (optional)
28. Airbag indicator lamp (disconnected)
29. Blackout light (disconnected)
CAUTION:
Different vehicle models differ in operational indicator lamps and alarm lamps.
Low beam indicator lamp
This indicator lamp will be on when the

combination switch left handle is at low beam
position.
Parking brake indicator lamp

When the driver pulls the manual valve control
lever backwards to the brake locking position, this
lamp will be on to remind the driver that the vehicle
is in braking mode. After this control lever is pulled
upwards to the release position, if the brake air
pressure is lower than (540±30) kPa, this indicator
lamp will be on; otherwise it will go out. When
starting the vehicle, it is necessary to check if the
indicator lamp goes out and the spring parking
brake is released.
Filament detection alarm lamp

Except for the trailer, this lamp will be on when any
filament of rear fog lamp, rear position lamp and
brake lamp is faulty. This function gives the driver
a hint of the working condition of the tail lamp.
Charging indicator lamp

This indicator lamp will be on when the key is
turned to ON position. It will go out when the
alternator works normally after the engine starts.
When the alternator does not work due to a fault
during driving, this lamp will be on.
CAUTION:
Never drive the vehicle for a long time
with this indicator lamp on.
Low oil pressure alarm lamp
This lamp will be on when the key is turned to ON

position, and off after the engine starts. And when
the oil pressure reduces abnormally in the course
of engine running, this lamp will be on to send an
alarm.
CAUTION:
Never keep driving when the low oil
pressure alarm lamp is on.
High beam indicator lamp

This indicator lamp will be on when the lamplight
combination switch is turned to high beam position,
and it will be also on during dimming operation.
Exhaust brake indicator lamp

This indicator lamp will be on when the exhaust
brake works. See Page 34 for exhaust brake
switch. When driving down the hill, proper
application of the engine exhaust brake can keep
the vehicle speed within the safe range.
Rear fog lamp indicator lamp

After either the front fog lamp or high beam or low
beam is turned on, this indicator lamp will be on
when the rear fog lamp is switched on.
Air dryer heater indicator
This indicator lamp will be on when the air dryer

heater switch is connected.
Seat belt indicator lamp

This indicator lamp will be on to give an alarm
when the driver does not wear the seat belt.
Door ajar alarm lamp

This lamp will be on when any door is open.
Front fog lamp indicator lamp

After the clearance lamp is turned on, this indicator
lamp will be on when the front fog lamp is switched
on.
The installation of this indicator lamp depends on
the configurations of specific vehicle.
Air filter clog alarm lamp
When this lamp is on, it means large intake

resistance of engine air filter, clogged intake air
flow, worse dynamic property and economic
efficiency of the engine, causing the vehicle unable
to continue running. In this case, the vehicle
should be stopped for cleaning or replacement of
the air filter until the lamp goes out.
CAUTION:
Make sure to clean and replace the air
filter element according to the
maintenance cycle if this lamp is not
on. Where this lamp is on, do not
perform maintenance according to
the maintenance cycle, but clean and
replace the element immediately.
Tractor ABS malfunction indicator lamp

It is only for the vehicle with ABS.
When the tractor key is at ON position, ABS will
make self-inspection (the ABS solenoid valves
make pull-in sound successively), and then this
indicator lamp will be on for about 3 s and then go
out. If this indicator lamp stays on, it indicates that
the ABS is faulty. In that case, press and hold the
ABS flash code diagnostic switch (see Page 29)
for 1-3 s, and the ABS fault flash code indicator
lamp will flash fault code. Please contact the
Technical Service Center (Station) authorized by
Dongfeng Commercial Vehicle Company of
Dongfeng Motor Co., Ltd. for vehicle inspection
and maintenance in time.
Low water level indicator lamp

vehicle.
When the key is turned from OFF to ON position,
this indicator lamp will stay on for 3 s and then go
out. When the coolant level in the engine auxiliary
water tank is lower than the specified limit, this
indicator lamp will be on. And meanwhile the
buzzer on the instrument will sound.
CAUTION:
Continuous driving with insufficient
coolant will result in overheating and
damage of the engine.
Instrument buzzer warning

Not only the buzzer will sound but also the corresponding alarm lamp on the instrument will be on in
case of high water temperature alarm, low water level alarm, and low air pressure alarm.
Mileage Display Screen

1. Trip meter
2. Odometer
Trip meter includes the trip meter a and trip meter
b.
In case of trip meter a, pressing and holding trip
meter reset knob for a long time will reset trip
meter a;
In case of trip meter b, pressing and holding trip 1. Trip meter 3. Trip meter reset
meter reset knob for a long time will reset trip knob
meter b; 2. Odometer
Pressing trip meter reset knob will switch between
trip meter a and trip meter b.
Backlight adjusting knob

The right knob is used to adjust the luminance of
instrument backlight.
Turn the knob leftwards to increase the luminance
of instrument backlight
Turn the knob rightwards to decrease the
luminance of instrument backlight
Master power switch
Electromagnetic type
This switch can be used to connect or cut off the
power of the whole vehicle. Before turning off the
power switch, open the buckle and then cut off the
power of the whole vehicle. Power should be cut
off during the servicing and maintenance of
electrical system of the vehicle to protect electrical
equipment.
CAUTION:
The master power switch shall never
be turned off when the engine is
running.
Rocker Switch
Front fog lamp switch

In the case of driving on a foggy day, when the
lamplight combination switch is in the clearance
lamp position, turning on this switch will turn on the
front fog lamp.
The installation of this switch depends on the
configurations of specific vehicle.
Rear fog lamp switch

When the lamplight combination switch is set to
high beam or low beam position (see Page 32) or
the front fog lamp is switched on, turning on this
switch will turn on the rear fog lamp.
Hazard alarm lamp switch

When the hazard alarm lamp switch is turned on,
the front, rear, left and right turn lights will all be on
and flash to warn other vehicles.
Air and electric horn transfer switch
During driving, operate this switch to switch

between electric horn and air horn.
Air dryer heater switch

This is the current control switch of dryer’s heater.
When this switch is ON, the dryer heating indicator
lamp will be on at the same time. When the
ambient temperature is below 5°C, please turn on
this switch. When the ambient temperature goes
up to 20°C, the electric heater will be cut off
automatically. When the ambient temperature is
above 10°C, turn off this switch.
ABS flash code diagnostic switch (optional)

If the tractor ABS malfunction indicator lamp (see
Page 26) stays on, it means that the ABS is faulty.
After this switch has been on for 1-3 s (during this
period, the vehicle must be immobilized), the ABS
malfunction indicator lamp will flash several times.
Determine the flash code and find out the fault in
accordance with flashing times.
Speed governor diagnostic switch (optional)

vehicle.
After the speed governor diagnostic switch is
connected (during this period, the vehicle must be
immobilized), the ABS malfunction indicator lamp
will flash several times. Determine the flash code
and find out the corresponding fault in accordance
with flashing times. See Page 30 for speed
governor diagnostic switch (optional).
Preheating controller
It is only for the Cummins engine.
When the outside temperature is below 0°C, it will
be difficult for the engine to start. In that case, the
driver may connect the air preheater switch before
starting the engine. Then the preheating controller
will work, and the preheating indicator lamp on the
instrument will be on indicating that the engine
preheater starts working. Preheating time should
be 50 s at the most. If the preheating time exceeds
50 s, the preheating controller will cut off the
preheater, and the preheating indicator lamp on
the instrument will be off. At that time, the driver
can start the engine.
CAUTION:
The preheater switch should be
turned off after the engine starts.
Electric stop controller

For the vehicle equipped with the electric stop controller, when the key is back to the original position
from ON position, releasing the electric stop controller rod will cut off the fuel circuit of the fuel injection
pump, and then the engine will stop.
Combination Switch (without cruise control)

1. Horn and lamplight combination switch 2. Exhaust brake switch, windshield wiper and
washer switch
Horn switch
Press this switch to sound the horn.
Lamplight combination switch
This switch is the combination of front position

lamp, end-outline marker lamp, marker lamp, rear
position lamp, rear end-outline marker lamp, side
marker lamp, headlamp, instrument lamp, license
plate lamp, overtake lamp, dimmer and turn light
switches.
Lamplight switch
1. Lamplight slip ring 4. Headlamp mark
Turn the lamplight slip ring of the combination
switch control lever to switch on the following 2. Lamplight off 5. Lamplight mark
lamps: mark
Clearance lamp: when the lamplight mark is 3. Clearance lamp
aligned with the clearance lamp mark, the front mark
position lamp, rear position lamp, end-outline
marker lamp, marker lamp, license plate lamp, side
marker lamp and instrument switch lamp will be
on.
Low beam: the low beam will be on when the
lamplight mark is aligned with the headlamp mark,
and the switch lever is at low beam position (see
Page 33 for dimmer switch and overtake lamp
switch).
High beam: the high beam will be on when the
lamplight mark is aligned with the headlamp mark,
and the switch lever is at high beam position (see
Page 33 for dimmer switch and overtake lamp
switch).
The clearance lamp will be on as well when the low
beam or high beam is on.
Turn light
When the control lever is turned forward, the front
right turn light, rear right turn light and right turn
light will be on; when the control lever is turned
backward, the front left turn light, rear left turn light
and left turn light will be on.
Dimmer switch and overtake lamp switch
The dimmer switch must be used in the case of

opposite direction driving at night. Turn the
headlamp on, and push the combination switch
control lever up and down to realize the alternation
between low beam and high beam. Push the
control lever downward from the low beam
position, and the high beam will stay on. In normal
driving, lift the control lever to the highest point
regardless of service conditions of other lamplight,
and then the overtake lamp (high beam) will be on.
After being released, the control lever will return to
the original place automatically and the high beam 1. Overtake lamp 3. High beam
will go out. 2. Low beam
Windshield wiper and washer switch

1. Pressing the top button on the control lever
can splash the washing fluid onto the glass
continuously. When being released, the
button will return to the original place
automatically. Turn the slip ring to perform
wiping function:
2. The wiper motor will stop when the wiper 1. Wiper mark 2. Slip ring
mark is aligned with “0”.
3. The wiper motor will work at low speed when
the mark is aligned with “I”.
4. The wiper motor will work at high speed when
the mark is aligned with “II”.
CAUTION:
1. Please use the wiper together
with the washer so as to prevent
windshield scratch.
2. Never use the washer without
washer fluid.
Exhaust brake switch
1. Push the switch control lever forward to ON

position. If the accelerator pedal and the
clutch pedal are released, the exhaust brake
will work and the exhaust brake indicator lamp
will be on. And if the accelerator pedal or the
clutch pedal is depressed, the exhaust brake
will be released automatically and the exhaust
brake indicator lamp will go out. The exhaust
brake will not work if the accelerator pedal or
the clutch pedal is depressed.
2. After the switch control lever is pulled 1. Switch on 2. Switch off
backward to OFF position, the exhaust brake
will stop working and the exhaust brake
indicator lamp will go out.
CAUTION:
When driving downhill on a long
slope, please apply the exhaust
brake, and turn on the exhaust brake
switch before downhill.
Key switch
1. LOCK (locking position): keys can only be

inserted and taken off at LOCK position.
2. ACC (accessory position): turn the key
clockwise to ACC position to electrify related
accessories.
3. ON (ignition position): turn the key clockwise
to ON position to enter into ignition state. At
this time, the instrument will start working.
4. START (start position): turn the key clockwise to
START position to start the engine. When
released, the key will return to ON position
automatically.
CAUTION:
1. It is forbidden to turn the key to
START position when the engine
is running to avoid engine
damage.
2. Do not start for a long time or
frequently; otherwise battery
electricity loss or starter damage
will be caused.
3. The time to start the engine each
time should not exceed 30 s and
the interval between two
successive starts should be 2
min at least.
4. For the sake of safety, make sure
to depress the clutch pedal when
starting the engine.
5. When the engine stops, wait for
20 s and then switch off the
power.
Ventilations
Window regulator switch

Turn the handle clockwise, and the door window
will rise; contrarily, the window will lower.
Power window regulator switch

Switch at driver’s side
Switch at passenger's side: this switch is designed
to control the lifting and lowering of power window
on the driver's side.
on the right door.
WARNING:
1. During the operation of the
power window, if something or
someone is stuck between the
window and the door frame, 1. Switch at driver’s 2. Switch at
always make the window move in side passenger’s side
reverse direction to get rid of the
stuck conditions.
2. When the driver operates the
power window regulator switch
at passenger's side, the driver
must make sure that no any
obstacles obstruct the normal
closing of the window.
3. The driver must make sure that
the passenger can correctly use
the power window regulator
switch.
4. During the lifting of the power
window, it's forbidden to put the
head or arm out of the window.
Switch at passenger’s side

on the right door.
1 Switch at passenger’s side
Climate Control System

HVAC controller
1. Mode control knob 3. Temperature control knob

2. A/C button 4. Fan and inner & outer circulation control
button
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 blowing, 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 & outer circulation control knob
Outer circulation gear: Fan OFF, and heater

system in natural ventilation mode (i.e. sucking
outside fresh air).
4 gears, LH: adjust the fan speed, i.e. adjusting the
blowing intensity. It has four gears, and the larger
the number, the higher the rotating speed. Once
any one of the gear is selected, the HVAC system
is in natural ventilation mode (i.e. sucking outside
fresh air).
Inner circulation mode: turn off the fan, and
activate the indoor air circulation of HVAC system.
4 gears, RH: adjust the fan speed, i.e. adjusting
the blowing intensity. It has four gears, and the
larger the number, the higher the rotating speed.
Once any one of the gear is selected, the HVAC
system is in indoor air circulation mode.
A/C button
Connected (lamp on): cooling (compressor works)
Disconnected (lamp off): non-cooling
Temperature control knob

Left half area (blue): cooling,
Right half area (red): heating
Heating method
When using heating function, please follow these steps:
1. Turn the temperature control knob to heating area.
2. Turn the fan and inner & outer circulation control knob to any position other than "inner circulation"
and "outer circulation".
To increase the heating speed, the following measures can be adopted:
1. Turn the temperature control knob to the rightmost (the maximum heating position).
2. Turn the fan and inner & outer circulation control knob to the higher speed gear on the right of “inner
circulation”.
Cooling method
When using cooling function, please follow these steps:
1. Turn the temperature control knob to cooling area.
2. Turn the fan and inner & outer circulation control knob to any position other than "inner circulation"
and "outer circulation".
3. Press the A/C button (the indicator lamp is on).
To decrease the cooling speed, the following measures can be adopted:
1. Turn the temperature control knob to the leftmost (the maximum cooling position).
2. Turn the fan and inner & outer circulation control knob to the higher speed gear on the right of “inner
circulation”.
3. Press the inner and outer circulation button (the indicator lamp is on).
CAUTION:
1. To use the cooling function, please start the fan before pressing the A/C button;
otherwise, the cooling function cannot be activated (the indicator lamp on A/C
button is not on).
2. To turn off the A/C, please press the A/C button (to turn off the indicator lamps of
the A/C button), and wait 2-3 min before turning off the fan. If the fan is turned off
first, A/C button will get disconnected at the same time.
3. When A/C compressor needs to be restarted after being switched off, please wait
for 3-5min; otherwise, the service life of compressor will be affected.
Natural ventilation mode

When using natural ventilation function, please follow these steps:
1. Turn the temperature control knob to cooling area.
2. Turn the fan and inner & outer circulation control knob to “outer circulation”.
Windshield defrosting and defogging

Turn the temperature control knob to heating area, mode control knob to defrosting and defogging gear,
and the fan and inner & outer circulation knob to ON to perform window defrosting.
Turn the temperature control knob to cooling area, mode control knob to defrosting and defogging gear,
and the fan and inner & outer circulation knob to “MAX SPEED” of “inner circulation” to perform window
defogging.
Precautions on use of climate control system
1. The heater employs engine coolant temperature to warm the air, so, when the coolant temperature
is not high, the temperature of delivered warm air will not be high either.
2. Do not use the heater for too long when the engine is stopped or is running at idle speed. Otherwise,
battery consumption may become larger and the normal driving will be affected.
3. When driving at a low speed, remember to engage the transmission to a lower gear to increase the
engine rotating speed. And it is the same case with driving on a comparatively long ramp way to
reduce engine's load.
4. Turn the temperature control knob to cooling area to reduce blast volume, in which case you can
press the inner and outer circulation button or turn up fan speed.
5. During indoor heating, the A/C button must be at OFF position to increase the heating efficiency and
reduce engine's energy consumption. A/C button is connected when pressed, and disconnected
when sprung back.
Air outlet adjustment

Turning thumb rod and thumb wheel can adjust the
air in horizontal direction; and rotating blades can
adjust the air in vertical direction.
1. Thumb 2. Thumb 3. Blade

wheel rod
Gear Lever
Transmission gear lever Dongfeng/Datong 6-speed transmission

Dongfeng/Datong 6-speed transmission is shown
in the right figure. Ensure to depress the clutch
pedal to the end upon gear shifting, and no shift
between forward gear and reverse gear can be
performed before the vehicle comes to a full stop.
When the gear lever is moved to R position
(reverse gear), the reversing lamp will turn on, and
the backup buzzer sends an alarm
CAUTION:
1. Ensure to depress the clutch
pedal to the end 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 air circuit between
high gear zone and low gear
zone.
3. Shifting between high and low
gear zone is prohibited when
driving down a slope.
4. Try to start the vehicle at 1st gear
according to the road conditions.
Manual valve control lever
The manual valve controlled spring air chamber

acts on intermediate and rear axle brakes for
parking brake or emergency brake. Please pull
backwards the manual valve control lever to brake
locking position in case of parking or emergency
braking. Lift the control lever when starting the
vehicle and releasing the brake, so that the control
lever will go back to brake releasing position.
WARNING:
When parking vehicle, be sure to
move the manual valve control lever
to locking position; otherwise, the
vehicle may move, which will lead to
damage or even personal injury.
1. Pull forward to 3. Pull upward
release
2. Pull backward to
brake
Methods to Release Spring Brake

vehicle.
Dual diaphragm type spring brake air chamber
Where the vehicle cannot be released from parking
brake and cannot start, it may be caused by the
pressure drop of spring brake air chamber, which
makes the spring brake operate automatically. In
such case, check the pipeline system or valves for
air leakage first; and timely eliminate the leakage,
if any. If the elimination is not possible, please
contact a technical service center (station)
1. Manual bolt 3. Washer
authorized by Dongfeng Commercial Vehicle
Company. 2. Nut 4. Dust plug
The emergency adjustment is as follows:
1. Remove release screw from the bracket, open
the rubber dust cap at the rear part of air
chamber, insert the hook end of release screw
into air chamber spring cavity and rotate to a
degree, and confirm the tray is hooked.
2. Install washer and nut, rotate the nut with
hand, and tighten the nut till the screw goes
out by about 40 mm with a wrench. The spring
braking is then released.
WARNING:
1. The release of parking brake on
spring brake chamber is limited
to emergency only. Running the
vehicle without parking brake is
quite dangerous and may result
in injury.
2. Ensure that the vehicle will not
slide automatically before taking
the above steps! The vehicle will
lose parking braking function
temporarily after the above steps
are taken!
3. Afterwards you must find out the
reason for deficient spring brake
air pressure for prompt repair.
After troubleshooting, be sure to
remove the release screw from
air chamber spring cavity to
restore the parking braking
function. And refit the release
screw to the bracket and tighten
it for next use.
Piston type spring brake air chamber
Where the vehicle cannot start resulting from the

failure to release the parking brake, it may be
caused by the drop of spring brake air chamber
pressure, which makes the spring brake operate
automatically. In such case, check the pipeline
system or valves for air leakage first; and timely
eliminate the leakage, if any.
Where the vehicle cannot start resulting from the
failure to release the parking brake caused by
insufficient spring brake air pressure, the spring
brake can be released by rotating the spring brake
release bolt with a spanner counterclockwise until
the bolt cannot be tightened any more.
1. Spring brake release bolt
WARNING:
1. The release of parking brake on
spring brake chamber is limited
to emergency only. Running the
vehicle without parking brake is
quite dangerous and may result
in injury.
2. Ensure that the vehicle will not
slide automatically before taking
the above steps! The vehicle will
lose parking braking function
temporarily after the above steps
are taken!
3. Afterwards you must find out the
reason for deficient spring brake
air pressure for prompt repair.
After troubleshooting, refit the
bolts to restore the parking
braking function.
Accessory System

vehicle.
Cigar Lighter
Press the cigar lighter directly to use it. And wait
for 10 s after it is released; then it will automatically
spring back to the original position when the
resistance wire in the front is heated red. At this
moment, you can pull it out to lamp the cigar. Put it
back in place after using it.
WARNING:
Never connect the cigar lighter for a
long period. It must be drawn out
manually if it fails to pop out
automatically.
Ash tray
Open the lid along the direction shown by the
arrow when using the 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:
For the sake of safety, always close
the ash tray before leaving the
vehicle.
Front reading lamp
They are installed on inner front roof. Pressing the

left and right switches will turn on the left and right
reading lamps, and pressing the switches again
will turn off the lamps.
DOOR position: when the switch is turned to
DOOR position, the interior lamp is controlled by
the driver door switch only. It turns on when the
driver door opens and turns off when the driver
door closes.
ON position: the interior lamp turns on once the
switch is turned to ON position regardless of the
position of the door. 1. Room lamp 3. Right switch
OFF position: the interior lamp turns off once the 2. Left switch 4. Reading lamp
switch is turned to OFF position regardless of the
position of the door.
Step lamp (option)

The installation of the step lamps depends on the
configurations of specific vehicle.
They are installed on the inner side of doors and
are used for step lighting. The left and right step
lamps are controlled by left and right doors
respectively. When the door is open, the step lamp
at corresponding side will come on; and when the
door is closed, the step lamp at corresponding side
will go out. 1. Step lamp
Glove Box

vehicle.
Open front roof glove box
There are two front roof glove boxes provided, one
on the left and one on the right, used to store
books, folders, CD and other objects weighed no
more than 3K preferably.
1. Left front roof 2. Right front roof

glove box glove box
Driver’s side glove box

It is used to keep cup, mobile phones and carry-on
small articles, etc.
Working lamp socket (medium configuration)

This socket provides power supply for the lamp
used for vehicle overhaul. It can also be used as
external power supply. The power output of this
socket is not controlled by the ignition switch but
the power switch of the complete vehicle. The
rated load of this socket is 24V, 10A.
CAUTION:
When getting power via this socket,
the load is strictly prohibited to
exceed the nominal capacity of the 1. Working lamp socket
socket.
Curtain
1. Upon extending curtain, put the rings on

curtain into corresponding hooks on the guide
rail, then evenly extend it along the guide rail,
overlap curtains with nylon buckle, and clip
metal fasteners at lower part of side/rear
curtain onto plastic buckles on the protection
board.
2. Upon collecting curtain, first release the nylon
buckle, then evenly collect the curtain along
the guide rail, and bind it with the fastener.
CAUTION:
Do not apply force to the lower end of 1. Curtain 2. Buckle
the curtain when extending the
curtain, or stamp on it.
Interior rearview mirror

Interior rearview mirror can be adjusted to any
angle.
Rearview mirror and under-view mirror

Exterior rearview mirrors, front under-view mirror,
wide-angle mirror and close-proximity rearview
mirror are installed on the passenger’s side. The
driver can adjust rearview mirror, front under-view
mirror and wide-angle mirror to realize best
rearview and down view effects.
1. Front under-view 3. Wide-angle mirror

mirror
4. Close-proximity
2. Exterior rearview rearview mirror
mirror
Radio & CD player

Radio & CD player (with MP3)
1. Power button 9. MP3 previous track

2. Mute button 10. Mode/band - BAND button
3. Display 11. Reset – RST button
4. USB gate 12. Volume +
5. MP3 next folder 13. Volume -
6. MP3 previous folder 14. Radio tuning knob
7. Clock – F/C button 15. Set - SEL
8. MP3 next track 16. USB play button
Retuning of MP3 player

1. Retune the unit before using it for the first time or after replacing the battery.
2. Retune this unit when the system hangs up.
3. Retune this unit by pressing the reset (RST) button using an object with sharp tip.
4. Pressing the reset (RST) button will clear certain content stored in the memory.
CAUTION:
1. Remember to turn off the PWR (power) before popping out or inserting the play box
so as to avoid document missing or U disc damaging.
2. Because the crystal oscillator in the U disc is precise, please protect your U disc for
safety.
3. The downloading format of U disc or SD card is MP3. This unit does not support
other format;
4. For downloading, U disc can be inserted to the external U disc interface of
computer directly.
5. Never connect the hard disc of more than 2G with this unit so as to protect it from
being damaged by extremely high current.
6. The vehicle with MP3 player may be a new model for you. However, you can operate
it skillfully in 10 min after reading this operation manual carefully.
Definition:
As this operation is controlled by CPU, some buttons are designed as a combo to realize different
controls when they are short or long pressed. These two words will be frequently used in the following
text, and are defined as follows:
Short press - Press and hold the button with hand and release it within 1 s;
Long press - Press and hold the button with hand and release it after more than 2 s.
Panel functions
1. Power button/volume control knob
Pressing and holding this button can turn off the power. This unit is so set 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 button to turn off the voice, and press it again to turn on the voice.
3. USB gate
Open this gate to accommodate a USB disk.
4. SEL - Audio mode/ menu setting button
(1) No matter which working state this unit is in, radio or tape play, press this button to realize the
following cyclic setting:
Press once Press once again Press once (Treble

(Volume (Bass again adjustment)
adjustment) adjustment)
Press once again
(Left/right sound
channel balance
adjustment)
When the LCD shows a certain function, pressing VOL+ or VOL- can enable increase or decrease of this
function respectively. The maximum value displayed of VOL is 32, BAS and TRE from -7 to +7, and BAL
from -5 to +5.
(2) Long press of MUTE button can select the following functions:
Press and hold SEL once Press it once again within 3s

Press it once again within 3s
Press SEL twice

again within 3 s
a. When the LCD shows DSPOFF, pressing the VOL+ button can realize the following audio effect mode
cycle:
Display DSP OFF Press once Press it once again

(Classical) (Popular)
(Audio effect mode off)
Press it once again
(Rock)
The selected audio effect mode will be confirmed without pressing the VOL+ button any more, and the
corresponding character for this audio effect mode will be displayed at the upper part of the LCD; if the
DSPOFF is displayed on the LCD indicating that the audio effect mode is turned off, pressing the VOL-
button can realize the switchover of various audio effect modes in the reverse sequence yet.
b. When the LCD shows BEEP OFF, pressing VOL+ or VOL- button can enable keystroke sound,
which means a click sound is given when any button is operated; pressing VOL+ or VOL- button
again can disable the click sound;
c. When the LCD shows LOUDOFF, pressing VOL+ or VOL- button can enable bass, with LOUD
displayed on the upper right corner of the LCD. Pressing VOL+ or VOL- button again can disable
the bass, and the LOUD on the upper right corner of the LCD disappears.
5. USB play button
Press this button to pause MP3 play, with PAUSE displayed on LCD; press this button again to resume
the MP3 play.
6. Radio tuning knob

Turn the radio turning knob to change the radio frequency and receive stations of different frequencies,
with the frequency of the required station displayed on LCD.
7. VOL+/VOL- button
Press VOL+ or VOL- button in radio mode or MP3 play mode to turn up or turn down the volume.
If you switch off the unit and then restart it, the volume setting before switch-off will be memorized. The
maximum displayed value of VOL is 32.
8. Reset – RST button
(1) Press the reset button before using this unit for the first time or after replacing the battery;
(2) When you accidentally disorder the programs of this unit, you can also press the reset button to
return the programs to normal;
(3) Since this button is seldom used normally, it is designed not to protrude from the panel. You can
insert a stick-shape object into the hole of the RST button and press it once to reset the unit.
9. Band/mode – BAND button
Press this button to switch to radio FM band; and press it again to switch to AM band.
10. MP3 next/previous track
Next/previous track selection: when playing the music with sound, press the “Previous’’ button to go
back to the previous track; and press the “Next" button to go to the next track.
11. Time adjustment F/C button
(1) In radio or play mode, the radio frequency or play time is displayed on the LCD. If you want to
view the current time, press this button once, and 5 s later, the original status will be recovered
automatically; however, if you are not willing to wait for 5 s, press this button again so that the
unit will return to the original status immediately;
(2) If the time is to be adjusted or calibrated, press and hold this button once to switch to time
adjustment regardless of the unit condition, when the time will be displayed and the "hour" field
will flash; press "Next +" button to increase the hour, or press and hold to increase the hour
continuously; similarly, press "-" button to decrease the hour. After the hour is calibrated, press
this button for conformation, when the "hour" field stops flashing, but the "minute" field starts
flashing. Press "+" or "-" button to increase or decrease minute respectively; after the
calibration is done, press this button again for confirmation, when the "minute" field stops
flashing, the calibrated time is displayed, and the original working status will be recovered
automatically after 5 s; however, if you press this button once, the unit will return to the original
working status immediately.
(3) The unit is designed with 12-hour & 24-hour time system, and the last time system setting will
be memorized. If you want to switch from 12-hour time system (AM for forenoon, PM for
afternoon) to 24-hour time system, press and hold this button when the "hour" field is flashing,
with the character AM or PM disappeared. Press and hold this button to switch 24h timing
system to the 12h timing system.
12. Next/Previous folder
In USB play mode, press this button to go back the previous folder;
In USB play mode, press this button to go to the next folder;
Tachograph
Please refer to accompanying Tachograph Operation Instructions of the vehicle for use of tachograph.
Comprehensive alarm
Tail lamp detection function (only for tractor, not trailer)
When the filament of the rear fog lamp, rear position lamp or brake lamp is broken, the filament detection
indicator lamp on the instrument goes on. This function is used to alert the driver of the working sate of
tail lamp.
Door ajar alarm function
When the clearance lamp is turned on with any door opened and the ignition switch at OFF position, the
internal buzzer of comprehensive alarm sounds to alert the driver to turn off the lamp when leaving the
vehicle.
Multifunction buzzer
Differential alarm
When the differential switch is pressed, the differential lock starts to play its role 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 turn off the differential switch in time after
driving out of a defective road. Otherwise, the differential will be damaged, causing excessive wear of
tyres.
Lifting alarm (disconnected)
When the lifting switch is pressed, the multi-functional buzzer sounds with a volume of 75 dB. The alarm
sound consists of a long tone and two short tones to alert the driver of safety.
PTO alarm (disconnected)
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 to alert the driver to turn off the PTO switch in time.
Standby signal alarm (disconnected)
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 high to low 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.
Fuse box label
Reserved
Wiper power Ignition Air dryer Brake lamp
A/C
interface lock relay
Warning: only the specified fuse is acceptable.

Working Power Radio & Compre
cassette hensive Cigar
lamp OFF window lighter
player alarm
Fuse clip
Quartz Central Front Power
N reading START 30
clock Locking switch voltage
lamp
PTO/mult
Stop Reverse Instrume Fluoresc
i-function Turn
switch switch nt ent lamp
al buzzer signal
lamp
Part No.
Rear fog Front Clearance Low beam High beam Horn

lamp fog lamp lamp
Tachograph
Part No.
NOTE: The fuse box is located under the cab front face shield.
Relay box label
Position Name Application Warning: only the specified relay is

1 Ignition lock ON, relay 1 acceptable.
2 Ignition lock ON, relay 2
3 Brake lamp relay
4 ACC relay
5 Horn relay
6 Brake relay
7 Wiper relay
8 A/C relay
9 High beam relay
10 Low beam relay
11 Clearance lamp relay
12 Rear fog lamp relay
Part No.
Position Name Application

1 A/C request relay Warning: only the specified relay is
acceptable.
2 ECU relay
3 A/C relay
4 Front fog lamp relay
5 R-gear relay
Exhaust brake
6 request relay
7 DBR relay
8 OFF relay
Part No.
Note: The relay box label is applied on the inner side of middle lower protective plate on
passenger’s side.
Adjustment of Steering Wheel
Pulling upward the adjusting lever of the steering

column from its locking position can make upward
and downward adjustment and fore-and-aft angle
adjustment of the steering wheel. After the steering
wheel is adjusted to a comfortable position, restore
the adjusting lever to the locking position.
WARNING:
Adjusting the position of the steering
wheel is strictly prohibited during
driving.
1. Locking position of steering column adjusting

lever
Towing Hook
Before using the towing hook, remove its cover as

follows:
Removal method for towing hook cover at driver’s
side
1. Remove the two bolts from the small pedal
with a screwdriver to take off the small pedal.
2. Rotate the buckle on towing hook cover by 45
45°with a slotted screwdriver, and remove the
towing hook cover.
Simply follow Step 1 to remove the towing hook
cover at passenger’s side. 1. Small step plate 3. Buckle
After using the towing hook, reinstall its cover 2. Bolt 4. Towing hook
properly by the steps opposite to the above. cover
Front face shield

Opening of front face shield
Pneumatics
1. Move inwards the lock handle at the left and
right lower corners of the face shield inside.
2. Pull the face shield from the bottom, when the
face shield will open automatically with the
help of air springs.
Manual
1. Move inwards the lock handle at the left and
right lower corners of the face shield inside.
2. Turn over the face shield, take down the
internal strut, and support it at the front 1. Front bracket
bracket.
Closing of front face shield
1. Lift up the face shield slightly, take the strut off

the front bracket and fix it into the snap at the
face shield inside.
2. Lower down the face shield gently, and apply
a force to the left/right lower corners to close
and lock the face shield.
Fire Extinguisher
The fire extinguisher is located under the

passenger seat. For the detailed operations, refer
to the instructions on the fire extinguisher body.
1. Fire extinguisher
Cab Tilting
CAUTION:
1. Always shut the engine down and park the vehicle on a level ground before tilting
the cab.
2. Note to check whether the space is sufficient when titling indoors.
3. Check that the parking brake control lever is at the braking position, and the gear
lever is at neutral position, and choke the wheels with triangle fillets.
4. Ensure the spread objects inside the cab are arranged in order and those which are
liable to fall during cab tilting are removed.
Manual cab tilting operation
Fig. 1 Fig. 2 Fig. 3

Latch Hydraulic lock
Fig. 4 Fig. 5 Fig. 6
Tilt the cab: pull the arresting pin open along the arrow (Fig. 1), move the handle along the arrow (Fig.
2, A-B), release the arresting pin, insert the rocker into the rocker arm, and rotate the rocker up and
down (Fig. 3) to lift the cab until the rocker cannot be rotated any more. Confirm that the oil cylinder pawl
is inserted into the groove.
Lower the cab: pull the arresting pin open along the arrow (Fig. 4), move the handle along the arrow (Fig.
5, B-A), and when the cab is lowered down in place, confirm that the hydraulic lock is locked (Fig. 6).
Keep the handle at position A.
CAUTION:
1. Make sure to shut down the engine and park the vehicle on a level ground.
2. Never tilt the cab on a slope.
3. No operation is allowed prior to proper cab lilting, and never pull the stopper
handle or rotate the lifting knob; the lifting knob shall be at lifting position in
service state.
Adding of Fuel
Open the fuel tank cap and add clean fuel of the
specified grade up to the 95% of its volume at
maximum.
1. Fuel tank cap
Warning Triangle
Warning triangle should be placed 50 m away from

the stopped vehicle, easily being noticed by the
drivers of the vehicles behind.
1. Warning triangle
Rear Protection
Rear Protection
Basic Requirements for Truck Side and Rear Protection
Applicable for trucks, vans and stake trucks.
Basic Requirements for Truck Side Protection
1. Cross rod 2. Vertical race 3. Diagonal race
The side guard consists of vertical brace and cross rod. The vertical brace is welded from bent steel pipe,
and is fixed to the side of subframe with bolts. The cross rod is manufactured from M-steel or L-steel,
and welded to the vertical brace.
1. Section dimension and material of trucks:
1).Category N2: 60X25X1.5mm; material: Q235 (see Fig. H-ZHCC-002 for section shape)
Rear Protection
2). Category N3: 120X30X1.8mm; material: Q235 (see Fig. H-ZHCC-003 for section shape)
2. The side protection can be a continuous plane, or be composed of one or more cross
rod(s)/combination of plane and cross rod. In application of cross rod structure, the distance
between two adjacent rods shall be no more than 300 mm, and the height of section shall be:
1). no less than 50 mm for N2 vehicle;
2). no less than 100mm for N3 vehicle.
3. The combination of plane and cross rod shall make a continuous side protection with smooth outer
surface and continuity as far as possible; the overlap for the adjacent components is allowed,
however, the external marginal edge shall be rearward or downward; the clearance between the
adjacent components in the longitudinal direction shall be no more than 25 mm, however, the rear
part shall not extend beyond the outside of front part. The round end of bolts and rivets can extend
beyond the outer surface for no more than 10 mm. This is also allowed for other parts only if they
are smooth and chamfered. All the marginal edges and corners shall be chamfered and the radius
no less than 2.5 mm.
4. The front edge of side protection shall meet the following requirements:
Rear Protection
1). For vehicles of category N2 and N3: the front edge shall be no more than 300 mm after the
circumferential tangent plane of the nearest tyre (see Fig. H-ZHCC-004), and the tangent plane
shall be the vertical plane being perpendicular to the longitudinal plane;
2). When the front edge of side protection is located in an open space, the front edge shall be
equipped with a continuous vertical member going through the whole height; for N2 and N3 vehicles,
both lateral surfaces of vertical member shall bent 100 mm inward, and the front end face bent at
least 50 mm and 100 mm rearward respectively.
Rear Protection
5. For vehicles of category N2 and N3: if the interval of front edge with the circumferential tangent
plane of the nearest tyre is 300 mm and located within the cab area, the clearance between the
front edge and the rear wall panel of cab should be no more than 100 mm (See Fig. H-ZHCC-004
and H-ZHCC-005), and when necessary, the front edge should be bent inward by no more than 45o.
In this case, the provision in Item 4 is not applicable.
6. The rear edge of side protection shall be no more than 300 mm before the circumferential tangent
plane of the nearest tyre (see Fig. H-ZHCC-004), and the tangent plane shall be the vertical plane
being perpendicular to the longitudinal plane.
7. For any point at the lower edge of side protection, the ground clearance shall be no more than 550
mm (see Fig. H-ZHCC-004).
8. The distance between the upper edge of side protection and its above member shall not exceed
350 mm (see Fig. H-ZHCC-004). The member refers to the part crosses or touches the tangent
vertical plane to the outer surface of tyre (exclude the projection of tyre when it touches the ground).
9. The side protection shall be of certain rigidity, fixed firmly (no looseness in spite of vibration), and be
manufactured from metal or other appropriate materials except for those installed to the vehicle
such as spare tyre, battery rack, air reservoir, fuel tank, lamp, reflector and tool kit etc. When 1 kN
static pressure is applied to the various parts of the device outer surface with a round flat punch (Φ:
220mm ± 10mm), the deformation resulting from the applied force shall meet the following
requirements: the deformation at the last 250mm part of side protection shall not exceed 30mm,
and that at the other parts not exceed 150mm.
Rear Protection
Basic Requirements for Truck Rear Lower Protection
The rear protection of trucks consists of rear

protection frame and cross rod.
The rear protection frame is bent by steel plate or
steel angle and bolted to the tail of framework (see
Fig. ZH-CH-001). The cross rod is formed by
rectangular steel tube and welded to the rear
protection frame (see Fig. H-GCC-007).
1. The end of traverse member at the rear lower
protection shall not bent to the rear end of
vehicle and the sharp part shall not be
rearward. The end of traverse member is
round, the fillet radius for the end shall not be
smaller than 2.5 mm, and the section height
for traverse member shall be no less than 100
mm.
2. In case of rear lower protection, the dimension
is 100 X 50 X 4.0 (mm) or 120 X 60 X 4.0
(mm), and the material Q235 rectangular steel
pipe.
3. The rear lower protection shall be close to the
rear part of vehicle as far as possible.
Rear Protection
4. The width of rear lower protection shall not be

more than the distance between the two
outmost points for wheels at two ends of rear
axle (exclude the tyre deformation), and the
horizontal distance between the outmost for
any end of rear lower protection and the
outmost of wheel of the rear axle in traverse
direction shall be no more than 100 mm (see
Fig. H-GCC-008). If a vehicle is equipped with
more than two rear axles, the longest one
shall prevail.
5. For vehicles can subject to adjustment under A: The traverse distance between the wheel
the condition of rear lower protection: outmost in both sides is no more than 100 mm.
1). For the entire width of rear lower
protection, the ground clearance of lower
edge shall be no more than 450 mm.
2) During the test carried out according to
static load test procedure and test conditions
specified in Appendix A in GB11567.2-2001,
the ground clearance for the application point
of test force on the device shall not exceed
500 mm.
3). Under an idle load condition, for the entire
width of rear lower protection, the ground
clearance of lower edge shall be no more than
450 mm.
6. For vehicles cannot subject to adjustment
under the condition of rear lower protection:
edge shall be no more than 550 mm (see Fig.
H-GCC-008).
550mm.
Rear Protection
7. After the test is carried out according to static

load test procedure and test conditions
specified in Appendix A (standard appendix)
in GB11567.2-2001 or according to the
moving barrier bump test procedure and test
conditions specified in Appendix B (standard
appendix) in GB11567.2-2001, the horizontal
distance between the rear end of deformed
device resulting from the application of static
loading force/impact of moving barrier and the
rear end of vehicle in the longitudinal direction
shall not exceed 400 mm (see Fig.
H-GCC-009).
Rear Protection
Basic Requirements for Engineering Vehicle Side and Rear Protection

The requirements are applicable to dump truck, concrete mixer, fuel tank truck and bulk cement truck.
Basic Requirements for Engineering Vehicle Side

Protection
The side guard consists of vertical brace and cross
rod. The vertical brace is welded from bent steel
pipe, and is fixed to the side of subframe with bolts
(see Fig. H-GCC-001). The cross rod is
manufactured from M-steel or L-steel, and welded
to the vertical brace (see Fig. H-GCC-002).
Side guard
Cross rod
1. In case of engineering vehicle, the section

dimension is 100 X 35 X 1.8 (mm) (refer to
Fig. H-GCC-004) or 120 X 30 X 1.8 (mm)
(refer to Fig. H-GCC-003), and the material
Q235.
2. The total width of vehicle shall not increase
after the installation of side protection whose
major part of outer surface is no more than
120 mm from the outmost (max. width). At
least 250 mm of protection rear part shall be
no more than 30mm from the outmost of rear
tyre (exclude the projection of tyre when it
touches the ground).
Rear Protection
3. The side protection can be a continuous plane, or be composed of one or more cross
rod(s)/combination of plane and cross rod. In application of cross rod structure, the distance
between two adjacent rods shall be no more than 300 mm, and the height of section shall be:
1). no less than 50 mm for N2 vehicle;
2). no less than 100mm for N3 vehicle.
4. The combination of plane and cross rod shall make a continuous side protection with smooth outer
surface and continuity as far as possible; the overlap for the adjacent components is allowed,
however, the external marginal edge shall be rearward or downward; the clearance between the
adjacent components in the longitudinal direction shall be no more than 25 mm, however, the rear
part shall not extend beyond the outside of front part. The round end of bolts and rivets can extend
beyond the outer surface for no more than 10 mm. This is also allowed for other parts only if they
are smooth and chamfered. All the marginal edges and corners shall be chamfered and the radius
no less than 2.5 mm.
5. The front edge of side protection shall meet the following requirements:
1). For N2 and N3 vehicle: the front edge shall be no more than 300 mm after the circumferential
tangent plane of the nearest tyre (see Fig. H-GCC-005), and the tangent plane shall be the vertical
plane being perpendicular to the Iongitudinal plane;
2). When the front edge of side protection is located in an open space, the front edge shall be
equipped with a continuous vertical member going through the whole height; for N2 and N3 vehicles,
both lateral surfaces of vertical member shall bent 100 mm inward, and the front end face bent at
least 50 mm and 100 mm rearward respectively.
Rear Protection
6. The rear edge of side protection shall be no more than 300 mm before the circumferential tangent
plane of the nearest tyre (see Fig. H-GCC-005), and the tangent plane shall be the vertical plane
being perpendicular to the Iongitudinal plane.
7. For any point at the lower edge of side protection, the ground clearance shall be no more than 550
mm (see Fig. H-GCC-005).
8. The distance between the upper edge of side protection and its above member shall not exceed
350 mm (see Fig. H-GCC-005). The member refers to the part crosses or touches the tangent
vertical plane to the outer surface of tyre (exclude the projection of tyre when it touches the ground).
9. The side protection shall be of certain rigidity, fixed firmly (no looseness in spite of vibration), and be
manufactured from metal or other appropriate materials except for those installed to the vehicle
such as spare tyre, battery rack, air reservoir, fuel tank, lamp, reflector and tool kit etc. When 1 kN
static pressure is applied to the various parts of the device outer surface with a round flat punch (Φ:
220mm ± 10mm), the deformation resulting from the applied force shall meet the following
requirements: the deformation at the last 250mm part of side protection shall not exceed 30mm,
and that at the other parts not exceed 150mm.
Rear Protection
Basic Requirements for Engineering Vehicle Rear Lower Protection

The engineering vehicle can apply adjustable and fixed rear guard.
The adjustable rear guard consists of angle

bracket, traverse bracket and cross rod.
The angle bracket of rear guard is manufactured
from bent channel steel, and welded to the rear
end of vehicle frame (see Fig. H-GCC-006). The
traverse bracket of rear guard is bent from a steel
plate, the cross rod is manufactured from
rectangular steel pipe, and the bracket and the rod
are welded together. A row of standard holes are
drilled on the traverse bracket of rear guard, and
connected to the angle bracket with the bolts; and
two rows of mounting holes are drilled on the angle
bracket of rear guard. In this case, the distance
between the rear guard and the rearmost of
vehicle and the ground clearance for the guard can
be adjusted by adjusting the mounting position of
cross member.
The fixed rear guard consists of guard bracket,
angle brace and cross rod.
The guard bracket is manufactured from bent
channel steel or angle steel. The angle brace
manufactured from channel steel or angle steel is
applied to reinforce the bracket inside, the cross
rod is welded to the guard bracket and the guard
bracket to the rear end of vehicle frame (see Fig.
H-GCC- 007).
1. The end of traverse member at the rear lower
protection shall not bent to the rear end of
vehicle and the sharp part shall not be
rearward. The end of traverse member is
round, the fillet radius for the end shall not be
smaller than 2.5 mm, and the section height
for traverse member shall be no less than 100
mm.
2. In case of rear lower protection, the dimension
is 100 X 50 X 4.0 (mm) or 120 X 60 X 4.0
(mm), and the material Q235 rectangular steel
pipe.
3. The rear lower protection shall be close to the
rear part of vehicle as far as possible.
Rear Protection
4. The width of rear lower protection shall not be

more than the distance between the two
outmost points for wheels at two ends of rear
axle (exclude the tyre deformation), and the
horizontal distance between the outmost for
any end of rear lower protection and the
outmost of wheel of the rear axle in traverse
direction shall be no more than 100 mm (see
Fig. H-GCC-008). If a vehicle is equipped with
more than two rear axles, the longest one
shall prevail.
5. For vehicles can subject to adjustment under A: The traverse distance between the wheel
the condition of rear lower protection: outmost in both sides is no more than 100 mm.
edge shall be no more than 450 mm.
2) During the test carried out according to
static load test procedure and test conditions
specified in Appendix A in GB11567.2-2001,
the ground clearance for the application point
of test force on the device shall not exceed
500 mm.
450 mm.
6. For vehicles cannot subject to adjustment
under the condition of rear lower protection:
edge shall be no more than 550 mm (see Fig.
H-GCC-008).
550mm.
Rear Protection
7. After the test is carried out according to static

load test procedure and test conditions
specified in Appendix A (standard appendix)
in GB11567.2-2001 or according to the
moving barrier bump test procedure and test
conditions specified in Appendix B (standard
appendix) in GB11567.2-2001, the horizontal
distance between the rear end of deformed
device resulting from the application of static
loading force/impact of moving barrier and the
rear end of vehicle in the longitudinal direction
shall not exceed 400 mm (except that in the
process of measurement the vertical ground
clearance is greater than 3m when the vehicle
is unloaded) (see Fig. H-GCC-009).
Starting & Driving
Starting & Driving

Engine Start (Cummins B Series Engine)
1. Carry out daily inspection.
2. Confirm that the gearshift lever is placed at the neutral position in low range.
3. Turn on the master power switch.
4. Cummins engine:
Turn the key switch to "ON" to start the engine; if the ambient temperature is too low to start the
engine, close the air preheating switch if an intake preheater is equipped, when the preheating
indicator comes on, indicating that the intake preheating is activated. If the preheating time
surpasses 50 s, the control will cut off the intake preheating automatically. After the preheating is
done, open the air preheating switch, and then start the engine.
5. Depress the accelerator pedal to MID position and the clutch pedal to the limit, and turn the key to
START to start the engine.
6. Immediately after the engine starts, release the key and release the accelerator pedal slowly to the
idle status, always checking the engine oil pressure within 15 s.
7. In cold start, depress the accelerator pedal to the limit first, and release it just before the starter
disengages.
8. Run the engine at idle speed for 3 to 5 min before running it under load.
9. If the engine fails to be started after three successive attempts, check if the fuel supply system
works normally.
CAUTION:
1. The time to start the engine by starter each time should not exceed 30 s. The
interval of two attempts should be 2 min at least.
2. Do not start for a long time or frequently; otherwise battery electricity loss or
starter damage will be caused.
3. For the sake of safety, make sure to press the clutch pedal when starting the
engine.
4. Never run the engine at idle speed for long time. Cummins engine can never run at
idle speed for more than 10 min, or the engine will be damaged.
Starting & Driving
Starting with cab tilted
1. Turn the manual valve control lever backward

to LOCK position, and turn the ignition switch
to ON position.
2. Place the gearshift lever to the neutral
position of the low range. Clear those
overturn-prone articles inside cab.
3. Chock the wheels with triangle fillets.
4. Follow the specified safe operation
procedures to tilt the cab. 1. Battery frame 2. Start and stop
switch
5. Pressing the start switch (black) of the engine
start-up and shut-down switch box can start
the engine.
6. Pressing the shut-down switch (red) can stop
the engine.
WARNING:
1. Do not touch the gear lever while
the engine is running after cab
tilting.
2. Do not lower the cab with engine
running.
Starting & Driving
Clutch Operation
Operation method
For vehicle equipped with transmission without synchronizer
When driving the vehicle, in order to shift high speed gear to low speed gear or inversely, gearshift
method of stamping clutch twice must be used, and the clutch is disengaged completely when shifting
gears. After any operation of clutch, do not place the foot on the clutch pedal.
1. Depress the pedal quickly 4. Depress the pedal quickly to disengage the
clutch completely
2. Shift the gear lever to the neutral position
5. Do gearshift
3. Release the pedal quickly
6. Release the clutch pedal to half-engaged
position quickly and then release the clutch
pedal slowly
Starting & Driving
For vehicle equipped with transmission with synchronizer

The following method is recommended in driving to shift high speed gear to low speed gear or inversely.
After any operation of clutch, do not place foot on the clutch pedal.
1. Depress the pedal quickly 3. Release the clutch pedal to half-engaged

position quickly and then release the clutch
2. Do gearshift
pedal slowly
Operation inspection
To ensure the service life and failure-free operation of synchronizer system, the easy release of clutch is
necessary absolutely, and also very important for normal operation of clutch booster. Check the clutch
disc for normal release every week according to the following steps:
1. Run the engine idly and depress the clutch pedal.
2. 20 s later, engage the reverse gear slowly.
If a click sound of gear grinding is heard upon gear shifting and engaging, check and readjust the clutch
and bleed off the clutch system after adjustment.
Starting & Driving
Transmission Operation
1. Upon gear shifting, the clutch must be disengaged completely, and the gearshift lever should be put
in place (for transmission without synchronizer, the double clutch gearshift method should be used).
2. No shift between forward gear and reverse gear can be performed before the vehicle comes to a full
stop.
3. Start with 1st gear or 2nd gear according to the road conditions, where 1st gear is preferred. Always
start the vehicle in climbing a slope or under heavy duty with 1st gear. Before starting the vehicle,
release the parking brake, and engage a gear and start only after the pressure rises to the value
required to release the brake.
4. Where the transmission is found involving such abnormalities such as unusual noises or strenuous
operation, stop the vehicle immediately to check and eliminate the fault.
5. Coasting with engine off is strictly prohibited at neutral gear.
6. When the vehicle needs towing, always disconnect the propeller shaft of rear axle or pull out the
axle shaft; otherwise, the transmission may be damaged.
Starting & Driving
Braking Operation

vehicle.
Antilock braking system (ABS)
It is only applicable to the vehicle model equipped
with ABS.
Antilock braking system (ABS for short) is a
mechanical and electrical integration system Tractor ABS malfunction indicator lamp
designed to prevent the locking of wheel due to
large braking force (especially on smooth road) to
get the most effective brake and brake operation
stability, and further to avoid traffic accidents and
to reduce the damage from accidents.
The system keeps the control of the vehicle
traveling direction in emergency braking, shortens
the braking distance (usually by about10％, larger
on smooth road and with higher vehicle speed), ABS flash code diagnostic switch
reduces traffic accidents, improves driving safety,
and lessens tire wear and cost of maintenance.
When the tractor ignition switch is at ON position, the ABS will make self-inspection (the solenoid valves
may make “pull-in” sound in turn). The tractor ABS fault indicator lamp will stay on for about 3 s and then
go out. If the tractor ABS malfunction indicator lamp stays on, it means that the ABS system is faulty.
Press and hold ABS flash code diagnostic switch for 1-3 s (the vehicle must be at static state when
carrying out this inspection), ABS malfunction indicator lamp flashes for several times. The
corresponding fault may be diagnosed by determining the flash code according to the flash times.
Please contact the Technical Service Center (Station) of Dongfeng Commercial Vehicle Company of
Dongfeng Motor Co., Ltd. immediately for troubleshooting.
Exhaust brake
Exhaust braking, as auxiliary braking, can mitigate brake-fade as a result of frequent application of the
service brake, thus to extend the service life of friction plate. See Page 34 for exhaust brake switch.
Starting & Driving
Operation of Governor Diagnostic Switch (Option)

Fault records reading/deleting button [5]
Read the fault records: press the button for at least 0.5 s (when the lamp (6) comes on), when the
malfunction indicator lamp (6) flashes and the fault output starts. The fault is expressed in numbers.
The flash codes correspond to the number. For the description of certain fault, refer to the DTC lists. The
fault will be displayed continuously before the fault button (5) is pressed again, which suggests that the
next fault is to be inputted. If no fault exists, the indicator lamp will return to the original status after the
fault button (5) is released. See Page 168 for Governor DTC List (option).
CAUTION:
The fault inquiry is allowed only when the vehicle is stopped.
Parking 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 25-35 m away from the expected parking
position.
2. Begin to release the pedal gradually at the point 5-6 m from the expected stop position.
3. Depress the brake pedal slightly to stop the vehicle completely when approaching the parking
position.
CAUTION:
1. Normally, never depress the brake pedal suddenly to the end and depress it all the
time other than in emergency. The sudden braking may result in personal injury or
vehicle part damage.
2. Avoid depressing the brake pedal repeatedly for times in a short period; otherwise,
a lot of compressed air in the air reservoir will be consumed, and thus the braking
effect of vehicle will be affected, making the vehicle out of control.
3. Apply the foot brake to stop the vehicle normally.
4. Do not apply the emergency braking except for emergency. In particular on a
slippery road, using emergency brake would be likely to result in lateral sliding and
other hazards.
5. After vehicle washing or passing through deep water pit, water may enter the brake
drum and reduce the braking efficiency. In this case, depress the brake pedal for
several times while driving the vehicle at a low speed to drain the water so as to
guarantee the normal operation of brake.
Parking
1. After the vehicle stops, shift the gear lever to neutral position of low range, and turn the manual
valve control lever to parking brake position.
2. Do not shut down the engine immediately when stopping the vehicle. The engine must run idly for 3
- 5 min. In particular, run the engine idly after the vehicle runs under heavy load or at a high speed
to prevent engine scuffing or turbocharger damage.
3. After the engine is shut down, turn off all switches, especially the power switch.
Slope Driving Method
1. When driving down a slope, the engine exhaust brake (see Page 34) should be used effectively to
keep the vehicle speed within the safe range. Exhaust braking switch should be turned on before
the vehicle begins running down the slope to ensure braking effect and smooth running furthest.
2. When the vehicle runs at low gear or runs down a slope, make sure that the engine speed will not
exceed the maximum allowable speed (the speed range indicated in red on the tachometer).
3. Test whether the service brake (foot brake) works normally before running down a steep or long
slope.
4. 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.
Maintenance & Adjustment

To prolong the service life of vehicle, guarantee the safety and pleasure of driving, always perform
careful and periodic maintenance on the vehicle. This manual describes some common maintenance
and adjustment methods. As for more detailed information about inspection and adjustment as well as
the parts replacement, please contact the nearest Technical Service Center (Station) of Dongfeng
Commercial Vehicle Company of Dongfeng Motor Co., Ltd.
Please refer to the attached Operation and Maintenance Manual of Cummins Engine for the
maintenance and service of Cummins engine.
Inspection and Adding of Coolant
Pressure cap
1. To check the coolant level, turn the ignition
key to ON position and check if the coolant
level warning lamp comes on. If the lamp
comes on and the buzzer sounds, please add
coolant. Alternatively, observe through
semitransparent expansion tank and in the
case of a level lower than the MIN mark of
expansion tank, adding of coolant is required.
2. Unscrew and open pressure cap to add
coolant till its level is at or below the MAX
mark of expansion tank.
3. Then tighten the pressure cap, and take
notice of sealing and working conditions.
CAUTION:
1. Before adding coolant, check the
engine and the radiator for
leakage, and repair it if any.
2. It is recommended to use
long-life antirust and anti-freeze
coolant. Never add running water
or hard water from well or river.
3. Drain the coolant off only after
the coolant temperature is below
50°C.
Drainage of Coolant
Open the water drain valve under the radiator to drain off the coolant in the cooling system.
CAUTION:
Drain the coolant off only after the coolant temperature is below 50°C.
Maintenance of Air Filter
Inspection and cleaning cycle of filter element

Service the filter element every 5,000km of normal
road surface running (or 4,000km in dusty region)
or when the air filter clog warning lamp comes on
(see page 26). Generally, only outer filter element
can be cleaned, and inner element cannot be
maintained but only replaced.
Change cycle
The inner and outer filter element must be
simultaneously replaced every 30,000km or when
the outer filter element has been cleaned and
serviced for more than five times.
Replace air filter element
1. Unscrew the butterfly nut of filter end cap by
hand and remove the end cap.
2. Screw out the fastening nut of the filter
element and remove the filter element.
3. Install each component following the
procedures reverse to removal.
1. Air filter case 6. butterfly nut

2. Inner element 7. Sealing ring
3. Butterfly nut 8. End cap
assembly
9. butterfly nut
4. Dust bag
5. Outer filter
element
Cleaning method of filter element
Blow the filter element clean with the compressed

air of 0.5Mpa or lower from inside to outside.
Inspection method of filter element
Put a lighted lamp inside the filter element to check
for damage and pinhole. Check whether the
washer is damaged, and replace it upon any
abnormality.
CAUTION:
1. Confirm that filter element and
end cap are mounted properly;
otherwise dirt may be absorbed,
sharply shortening the engine
service life.
2. Never clean the filter element
with gasoline or water.
3. When cleaning the cyclone hood,
note if it is damaged.
4. Check the sealing rings during
installation.
5. Do not remove the air filter when
the vehicle is running.
6. Tighten the filter element and
end cap nut, and install the
sealing ring of the end cap
properly. Prevent the rain into
the filter.
Drainage of Fuel Tank
If there is too much sediment in the fuel tank, a

great deal of impurities will enter the pipe and
accelerate the pollution of fuel primary filter, and
even clog the oil line. Therefore it is necessary to
drain the sediment out from the fuel tank in time.
Remove the drain valve at the bottom of the fuel
tank, and drain off the sediment and water at the
bottom of fuel tank. Afterwards, refit and tighten
the drain valve. 1. Drain valve
Maintenance of Cummins B Series Engine
Inspection and change of engine lubricating oil

Change cycle
Every 10,000km
Check of engine lubricating oil level
1. Park the vehicle on flat road, shut down the
engine for about 5 min, pull the engine oil
dipstick out, wipe it with clean rag and fit to
original position.
2. Pull the oil dipstick out again and observe the
oil level. The normal range should be between
the two mark lines. Add clean lubricating oil if
insufficient. Drain the oil from oil drain bolt if
excessive.
CAUTION: 1. Oil dipstick
Check the engine oil level when the

engine turns cold.
Change of engine oil
1. Drain off the lubricating oil from the oil sump

while the engine is hot. If the engine is cold,
please warm it up before changing the oil.
Run the engine until the coolant temperature
is up to 60°C, then shut off the engine and
immediately remove oil drain plug, to drain off
all oil and suspending contaminants in the
engine.
2. Wipe up the oil drain plug clean and refit it.
3. Replace the oil filter and clean the mating face
of filter seat oil seal.
4. Add new oil as required.
1. Oil sump 2. Oil drain port
5. Start the engine, and check the filter and oil
drain plug for leakage with engine idling. Shut
down the engine, wait for 5-10min, and check
and adjust the engine lubricating oil level until
it reaches the normal range.
CAUTION:
1. Always drain the oil after the
engine completely stops and
coolant temperature drops below
60°C.
2. Upon oil drainage, pay attention
to the oil temperature to avoid
scalding.
3. Never start the engine when the
lubricating oil level is below “L”
(Low) or above “H” (High).
Oil filter
Replacement cycle
Every 10,000km
1. Oil filter 2. Filter spanner
Replacement method
Dismount the oil filter with the special filter
spanner. To mount a new primary filter, wipe
mating face clean first, fill the filter with full clean
oil, and lubricate the rubber seal ring with little
clean oil, then mount the filter by hand. Tighten by Screw tightly
3/4 turn after the sealing surface fits with the
mating face. Start the engine, check if the sealing
surface is leaking oil, and if any, tighten again until
no leaking is found.
CAUTION:
1. Do not tighten the filter with a
spanner during the installation.
Otherwise the threads may
deform and the filter may be
damaged.
2. When mounting a new filter, note
whether its model conforms to
that required by this engine.
Fuel Primary Filter
Replacement cycle Fuel primary filter (without hand oil pump)

Every 20,000km (one-off fuel primary filter)
Replacement method
Dismount fuel primary filter with special filter
spanner. To install a new primary filter, wipe up the
mating face first, fill in the filter with clean fuel, and
mount the filter by hand. Tighten manually by 3/4
turn after the sealing surface is connected to the Tighten
mating face.
Draining of fuel primary filter

Shut off the engine and open the drain valve to
drain the water and sediment. Tighten the drain
valve if clean fuel flows out.
CAUTION:
1. Never tighten the fuel filter and
fuel primary filter with a filter
spanner during the installation.
Otherwise the threads may
deform and the filter may be
damaged.
2. Tighten the drain valve by hand
instead of any tools.
3. Do not open the drain valve
completely when draining water.
Fuel filter & oil mist separator
Replacement cycle
Every 20,000km
Replacement method
Dismount the fuel filter and fuel filter with oil mist
separator using special filter spanner. To install
new fuel filter and fuel filter with oil mist separator,
wipe up the mating face first, fill the fuel filter and
fuel filter with oil mist separator with clean fuel, and
mount the filter by hand. Tighten by 3/4 turn after
the sealing surface is connected to the mating
face. 1. Oil mist separator 3. Fuel filter
2. Drain valve
Drainage of fuel filter & oil mist separator

Shut off the engine and open the drain valve to
drain the water and sediment. Tighten the drain
valve if clean fuel flows out.
CAUTION:
1. Do not tighten fuel filter and oil
mist separator with filter spanner
during the installation. Otherwise
the threads may deform and the
filter may be damaged.
2. Tighten the drain valve by hand
instead of any tools.
3. Do not open the drain valve
completely when draining water.
Bleeding of Fuel System
Bleed the fuel system after finishing the following

operations.
1. The fuel is not full before installing a new fuel
filter and oil-water separator.
2. Replace the injection pump and high pressure
fuel pipe.
3. Replace fuel delivery pump and low pressure
fuel pipe.
Bleeding method of fuel system
1. Unscrew the bleed screw fixed on the oil 1. Fuel delivery 2. Bleed screw
intake pipe joint, press the fuel pumping pump
button of the fuel delivery pump fast and
frequently to bleed the remaining air inside the
low pressure fuel line until no air bubble exists
in the discharged fuel, and tighten the bleed
screw again.
2. Start the engine, unscrew the union nut fixing
the high pressure fuel pipe to the injector end,
discharge the remaining air inside the high
pressure pipeline, and then tighten the union
nut.
CAUTION:
1. No exhausting operation is
allowed when the engine
temperature is high.
2. The time spent on starting
engine must not exceed 30s, and
the interval between starting
operations shall be 2 min at least.
Maintenance of by-pass supercharger

1. Do not damage the thin push rod and actuator installed outside of the turbocharger.
2. Check the clamp spring at one end of push rod for damage or shedding, and check nut at middle of
push rod for looseness, contact service station in time if loose. User is not allowed to remove
by-pass valve mechanism or do any adjustment by himself.
3. Check the sealing at both hose ends, and check if the clamp is fitted properly and the hose is
damaged.
4. Use oil and diesel of specified grade; within 15s after start, notice the change of oil pressure. Heat
for 5 min at a low or moderate speed after start, and take special care of the case at low
temperature.
5. When the engine runs with heavy load for a long period, run it at idle speed for 3-5 min before
shutting it down.
6. Add clean oil through the supercharger inlet port, and prod rotator to rotate with hand when
replacing with a new by-pass supercharger.
7. "Accelerate - flameout - neutral coast" operation method is prohibited for the vehicle.
Inspection & adjustment of advance angle for fuel supply

The engine has been strictly adjusted before delivery and met the requirement of the national
engine can only be adjusted at appropriate service station designated by Dongfeng Motor Co., Ltd., and
with small advance angle for fuel supply, the engine represents insufficient power and the free
accelerating smoke rises. Inspect the advance angle of fuel pump, and the advance angle for fuel supply
must be adjusted to crank angle of 10°if too small.
Inspection of injector
The engine has been strictly adjusted before delivery and met the requirement of the national
engine can only be adjusted at appropriate service station designated by Dongfeng Motor Co., Ltd.
Injector blockage may lead to poor fuel atomization and large free accelerating smoke and steady-state
smoke. Inspect the injector and replace it if poor fuel atomization is found.
Inspection of Clutch Fluid Level
Normal change
Every 50,000km.
Under normal conditions, the level of the fluid
reservoir should be near the MAX mark. Add fluid if
the level is below MIN mark. Check the pipeline
system for leakage before filling. If any leakage
presents, please repair it before filling.
CAUTION:
1. Never use the brake fluid of 1. Clutch fluid reservoir
different quality or different
grades.
2. It is strictly prohibited to use
mineral oil as brake fluid, and
confirm that the clean brake fluid
is used.
3. Never have the brake fluid
contact any painted surface so
as to avoid damage to paint film.
4. Pay special attention to sealing
and preservation.
5. Never allow dirt or dust into the
reservoir.
Adjustment of Clutch
The clutch employs the hydraulic control system

consisting of master cylinder and booster.
Adjustment method of clutch pedal is described as
follows:
With the clutch pedal position unchanged, loosen
the locking nut of master cylinder push rod, push
the rod upward to the limit, and ensure that the
master cylinder clearance is 0.5-0.7mm. Finally
tighten the locking nut. It is unnecessary to adjust
the booster push rod. 1. Booster 2. Master cylinder
Bleeding of Clutch
Bleed the clutch control system when there is air in

it. Bleeding method
1. Fill the clutch fluid reservoir with brake fluid to
make the air reservoir pressure reach
650kPa.
2. Remove the booster dust cap, unscrew the
bleed bolt of booster and depress and release
the clutch pedal repeatedly until bubbles 1. Bleed hose 3. Fluid tank
come out.
2. Bleed bolt
3. Tighten the bleed bolt, and depress and
release the clutch pedal repeatedly. Depress
the clutch pedal, unscrew the bleed bolt to
discharge the air from the brake fluid, and
then tighten the bolt and release the clutch
pedal.
4. Repeat step 3 for several times until no air
comes out from the bleed bolt hole and the
driver feels that the clutch can be disengaged
completely.
Inspection and Change of Transmission Oil
Please refer to the specific configurations of your Dongfeng 6-speed transmission

vehicle.
Initial change
After running-in of 1,500-2,500km.
Normal change
Every 30,000km (in normal conditions);
Every 20,000km (the vehicle is under heavy load
working conditions or in the environment of serious
pollution for a long time).
Check method
1. Oil filler and level access hole
Unscrew the sealing plug of oil filler and level
access hole of the transmission to check the oil 2. Drain port plug
level. The oil level should be flush with the lower Datong 6-speed transmission
edge of the plug hole. Add the oil if insufficient.
Replacement method
Change the transmission oil when engine is hot.
Unscrew the oil drain plug to drain the oil in the
transmission first, then clean the screw plug (as
the magnet on the plug adsorbs the iron chips
accumulated in the oil) and refit it, then add new
lubricating oil through the oil filler and level access
hole until the oil level is flush with the lower plane
of oil filler.
CAUTION: 1. Filler plug
1. Low oil level may lead to bearing 2. Drain plug

and gear burnout, while high oil
level may lead to overheating
and oil leakage.
2. The breather plug should remain
unblocked all the time.
Maintenance & Adjustment of Brake
Manual adjuster
Normal inspection
Every5,000km
Clearance of brake drum and brake shoe and
friction plate:
At the center of brake shoe: 0.3 - 0.5mm (manual
adjuster)
0.6 -1.0mm
(automatic adjuster)
Method of local adjustment
1. Fit the ring spanner over the worm shaft
head, rotate the worm shaft to make the
friction plate 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 moment.
2. Check that the push rod travel of the brake
chamber is within 25±5mm.
CAUTION:
Check the brake clearance frequently
and adjust it in time if the braking is
weak. Attention should be paid to the
followings during adjustment:
1. Never change the push rod travel
by tightening the connecting fork
of brake chamber.
2. To adjust the rear brake, always
park the vehicle on flat place and
ensure the air reservoir pressure
is above 700kPa.
3. Chock the wheels at the front and
back, and after releasing the
parking brake, adjust the rear
brake clearance.
Automatic Adjuster

vehicle.
If the brake is equipped with an automatic adjuster,
the clearance between the brake shoe and brake
drum can be adjusted smaller automatically when
the friction plate is worn and the clearance
exceeds the set value, so as to reduce the
maintenance time and ensure driving safety.
During normal operation, add lubricating grease
from the grease nipple every 10,000km. Check the
reverse adjusting torque every 20,000km, namely
rotate the worm shaft counterclockwise (repeat
three times); if the torque is less than 26N·m,
replace the adjusting arm, and check if the part
assembly of the brake returns smoothly without
seizure during operation. 1. Tiny pin shaft 4. Connecting fork
Release the parking brake before driving the 2. Worm shaft 5. Pre-tightening nut
complete vehicle, and depress the brake about 3. Grease nipple
30-40 times with the air pressure at 300-400kPa so
that the brake clearance can be adjusted smaller
automatically.
Check the brake friction plate for wear regularly, so
as to avoid degradation of the braking performance
and damage to other parts due to excessive wear
of friction plate.
To replace the brake shoe, rotate the worm shaft to
keep the camshaft at the minimum opening
position. After the friction plate is replaced,
depress the brake pedal about 30-40 times with
the complete vehicle air pressure at 300-400kPa to
reduce the brake clearance. When the vehicle is in
service, the shoe clearance will be adjusted
automatically and continuously along with the
proceeding of running-in, till it is kept within the
designed reserved clearance range.
Method to adjust the brake clearance manually

For new vehicles or vehicles whose friction plate has been replaced, if the normal operation is affected
as the clearance between brake shoe and drum is incorrect or the clearance becomes smaller due to
thermal expansion of new friction plate or running in hilly region (frequent braking), the brake clearance
can be adjusted larger manually.
1. Fit the ring spanner over the worm shaft head, rotate the worm shaft to make the friction plate
contact the brake drum, and then rotate the worm shaft in reverse direction by 1/2-2/3 turn (larger
torque for reverse rotation of the worm shaft). The brake drum should rotate freely without
contacting any part at this moment. Alternatively, use a feeler gauge to measure and adjust the
brake clearance to a suitable range (0.6 - 1.0mm).
2. Check that the push rod travel of the brake chamber is within 35 ± 10mm (air pressure of 300kPa).
3. In case the automatic adjusting arm has been in service for a long time or has not been maintained,
lubricated in time, causing no rotation of worm shaft, remove the small pin shaft of the automatic
adjusting arm and repeat steps 1 and 2, and then put it into service In this case, where the
automatic adjusting function is not available any more, go to the service station to have the
automatic adjusting arm repaired or replaced.
CAUTION:
1. Never adjust the brake clearance by hand during normal use;
2. Check the friction plate for wear regularly to avoid brake failure due to excessive
wear of friction plate;
3. Never change the push rod travel by tightening the connecting fork of brake
chamber push rod when adjusting the brake clearance by hand;
4. To adjust the rear brake, always park the vehicle on flat place and ensure the air
reservoir pressure is above 700kPa.
5. Chock the wheels at the front and back, and after releasing the parking brake,
adjust the rear brake clearance.
6. In case of brake abnormality, immediately stop the vehicle and inspect the
operation of automatic adjusting arm and other components of braking system, and
take proper measures to eliminate the fault.
7. Always tighten the locking nut of connecting fork after adjusting the brake
clearance.
Disk brake
WARNING:
1. Never use pneumatic or electric wrench during all procedures;
CAUTION:
1. Inspection and maintenance of disk brake requires expert skill from service station
designated by Dongfeng Motor Co., Ltd.
Working principle
The product is characterized by floating caliper, with the friction plate compensated automatically by
mechanical adjustment mechanism. The adjustment mechanism driven through brake chamber propels
inside friction block to contact brake disc, moving the brake caliper laterally along slide so that the
outside friction block could contact with brake disc to enable braking function.
The adjustment mechanism guarantees the clearance value between the brake block and disc.
Method to adjust disk brake clearance

manually
Park the vehicle securely and completely, remove
the tyre, pull the caliper body towards wheel
outside till it can not be moved, and check the
clearance value between the outside friction block
and brake disc with feeler. If the clearance value is
out of allowed range, please maintain the
automatic adjustment mechanism for clearance.
Clearance from brake block to brake disc:
Disk brake Longzhong Youfin
Clearance value (mm) 0.6 - 1.2 0.7 - 1.2
Identification characteristics of disk brake

Location of identification
characteristic
Youfin: smooth surface without
words marked
Longzhong: with depressed
"CNLZ"
Testing of automatic adjustment mechanism for clearance

Structure I: the adjusting method is applicable to Youfin disc brake.
1. Plug cover
1. Locking bolt
2. Pressure plate
1. Park the vehicle securely and completely, remove the tyre, dismount pressure fork locking bolt, take
the fork off, move the caliper body and remove the internal brake block;
2. Take the brake head plug cover off;
3. Rotate the adjusting bolt clockwise to extend the push plate and counterclockwise to retract the
push plate, which indicates the automatic adjustment mechanism is normal. Otherwise, the
automatic adjustment mechanism may be faulty, and replace it or the brake;
4. Reassemble the brake after testing and maintenance.
Structure II: the adjusting method is applicable to Longzhong disc brake.
1. Locking bolt
2. Pressure plate
3. Inner brake block
1. Plug cover
2. Adjusting bolt
1. Park the vehicle securely and completely, remove the tyre, dismount pressure plate locking bolt,
take the plate off, move the caliper body and remove the internal brake block;
2. Take the brake head plug cover off;
3. Rotate the adjusting bolt clockwise to tighten the brake disc and counterclockwise to release the
brake disc, which indicates the automatic adjustment mechanism is normal. Otherwise, the
automatic adjustment mechanism may be faulty, and replace it or the brake;
4. Reassemble the brake after testing and maintenance.
CAUTION:
1. The lever should be able to rotate freely without blockage during adjustment.
2. The proper installation of plug is of great importance to dust and moisture
prevention of mechanical adjustment mechanism. The adjustment mechanism will
set the working clearance to normal value after several times of braking.
Inspection of brake caliper sliding
1. Park the vehicle securely and completely,

remove the tyre, and push/pull the brake
caliper with hand to check if the brake caliper
is sliding smoothly;
2. The brake caliper is normal if it can slide
smoothly; or otherwise check the brake
caliper;
3. If exceeding the maximum sliding resistance,
check if the brake caliper sliding is hampered
by dust and foreign matters etc.
The maximum sliding resistance: 100N.
Inspection of brake block

Inspection of brake block wear
Measure the distance from brake block bottom
plate A to friction surface B.
Inspection of brake block nonuniformity
The maximum nonuniformity is 1mm (measured at
each of 4 points).
In the case of nonuniform wear, check for normal
brake caliper sliding on the slide, and check if there
is dust between the brake block and push plate
and if the clearance adjustment function of
automatic adjustment mechanism is normal.
Brake block wear:

Thickness of friction material of new brake 21 20
block (mm)
Min. thickness of rest friction material (mm) 2 2
CAUTION:
1. Stepping on brake gently may result in accelerated wear of inside friction block.
2. The brake block must be replaced along with all brake blocks of two brakes on the
same axle.
Inspection of brake disc

Inspection of brake disc size
A= Thickness of new brake disc
B= Thickness of brake disc above wear limit, in
which case the brake disc must be replaced
Brake disc parameters:

Thickness of new brake disc (mm) 45 45
Thickness of brake disc above wear limit 37 37
(mm)
Max. thickness difference (mm) 1 1
Inspection of brake disc crack
Crack depth at B
a= Width of friction plate contact surface area

A= Spots distributed on surface, permissible
B= Cracks with both depth and width less than 1.5mm, radial and that with length less than3/4 of friction
plate contact surface area, permissible
C= Cannelure ring and cracks with depth less than 1.5mm, permissible
D= Radial penetrated crack, non-permissible
CAUTION:
1. The brake disc must be replaced along with all brake discs of two brakes on the
same axle.
Inspection of friction plate wear

Structure I: Disk brake (Youfin)
Alert reference surface
Initial position Wear limit position
1. Wear bar 2. Compression spring
The mechanical wear indication device is used to inspect friction plate wear through wear bar.
Press the wear bar with hand, and replace the friction plate if the wear bar reaches the limit position
(alert reference surface).
Initial position: 18mm.
Wear limit position: 0mm
Structure II: Disk brake (Longzhong)

Press the rubber sealing ring inward, and replace
the friction plate when the rubber sealing ring turns
flush with the sealing cap end face.
L= distance from end face of rubber sealing ring to
that of sealing cap.
Initial position: L=17.5mm.
Wear limit position: L=0mm
1. Compression 3. Sealing cap

spring
4. Rubber sealing
2. Wear bar ring
CAUTION:
1. If the rubber sealing ring is damaged during the inspection, replace it immediately.
Inspection of Brake Pedal Travel
1. Step on the brake pedal slightly to check if the

free travel is within 12 -18mm.
2. There should be no seizure when the brake
pedal is depressed to the limit.
3. There should be a bleeding sound when the
pedal is released.
Inspection of air dryer
The air dryer is used to dry the compressed air Air dryer heater switch
from compressor, thus supplying dry and clean air
to the air reservoir.
Replacement cycle
Cylinder or desiccant of air dryer: every 30,000 km
or 6 months, or shorter if the vehicle always works
under adverse conditions (such as moist or hilly
area).
Inspection of water accumulation Air dryer heater indicator
Check the air reservoir for water accumulation
every week (In winter or in chilly area, it is
recommended to do the check at the end of each
working day). For this purpose, pull the water drain
valve under the air reservoir or the steel hook
under the reservoir frame. If any water presents,
replace the cylinder or desiccant immediately.
Inspection of exhaust outlet

If air leakage is detected at the exhaust outlet of the air dryer assembly during inflation before vehicle
start, please check the exhaust valve. If the exhaust outlet cannot be closed tightly due to foreign
matters, oil dirt or others, please clean the exhaust valve. The air reservoir is designed with a certain
pressure range, and if the pressure in the pipeline exceeds the upper limit, it is normal that the air dryer
exhaust outlet will bleed air for pressure relief. Only when the air pressure is consumed down to the
lower limit will the exhaust valve close, and the pipeline system will be re-inflated.
Heating of air dryer
If the ambient temperature is lower than 5℃, activate the electric heater of the air dryer to prevent the
disability of dryer due to icing at exhaust outlet. Turn on the air dryer heater switch (see page 29), on the
instrument panel, and the heating indicator lamp will come on simultaneously (see page 25).
CAUTION:
Please check the air reservoir for water accumulation one month before frosting every
winter. Replace the cylinder or desiccant at this point to ensure air drying effect and
prevent the air circuit from freezing due to water accumulation.
Inspection and Change of Power Steering Hydraulic Oil
Initial change
Normal inspection
Every 5,000km
Change cycle
Every 20,000 km or in case of oil deterioration or
too many impurities.
Frequently check the oil level and check for oil
deterioration in the oil tank when the vehicle is in
service, and add or change oil in time upon
detection of any abnormal conditions. Wipe the oil
tank clean when checking the oil level. Then
unscrew the oil dipstick assembly, clean and refit 1. Oil filler cap with dipstick
the oil dipstick, then remove it and observe oil
level. If the oil level is not between the upper and
lower marks of the oil dipstick, hydraulic oil of the
same designation should be added.
Replacement method
1. Wedge the front and rear of the rear wheels
with triangular blocks, engage the
transmission at neutral gear, and jack the
front axle to raise the tyres of both sides off
the ground.
2. Wipe the oil tank clean firstly, unscrew the
tank cover fastening nut to open the tank
cover, unscrew the drain bolt of the steering
gear and turn the steering wheel repeatedly to
the both limits, to drain the residual oil out of
the oil pump and oil tank. Run the engine idly
when necessary, and turn the steering wheel
to the left and right limits for several times until
that no oil flows out from the port.
3. Tighten the drain bolt after confirming that the
oil in system has been drained completely,
and replace or clean the oil tank filter element.
4. Add clean oil to the oil tank, run the engine at idling speed for 3-5s, then stop the engine and check
the oil level again and add oil. Repeat the above procedures for three times at least. Either quick
drop of oil level or empty oil tank is not allowed during the entire oil filling process, for fear of the
system with air intaken.
5. Run the engine at idling speed for 2min and then stop the engine to check if the oil level meets the
requirement.
6. Run the engine, turn the steering wheel from left limit to right limit and repeat this for many times
until the oil level stops dropping and no bubbles occur. Add the oil to the level required (that is,
between the upper and lower marks of the oil dipstick). Repeat this step several times until the
hydraulic oil is filled between the upper and lower scale of the oil dipstick.
CAUTION:
1. Do not add the hydraulic oil with engine running.
2. Make sure to replenish with the hydraulic oil of the same grade.
3. With engine idling, turn the steering wheel back and forth to facilitate air bleeding in
the system.
4. Always shut down the engine when checking the oil level.
5. Never let the steering wheel stay at the limit position for more than 15s, but in this
case, it is required to slightly turn the steering wheel backwards so as to prevent
steering booster pump from any damage.
Inspection of Steering Wheel Free Turn
When doing maintenance every 5,000km, check

the free turn of steering wheel. It is specified that
the leftward/rightward free turn at middle position
should not exceed 15°.
Perform the following adjustments upon excessive
free turn:
1. Check and adjust the clearance of front wheel
hub bearing.
2. Check if the joints of tie rod and drag link are
loose, and adjust them if so. Adjust the drag
link joint as follows: tighten the screw plug
completely with a special bent spanner, screw
it back by 1/4-1/2 turn and lock the screw plug
by split pins
3. Check the fitting conditions between ball pin
cones of tied rod/draglink and tapered bores
of the upper and low arms, tighten the ball pin
nut, tap the joint position and screw the nut by
1/3 -1/2 turn to allow the exact insertion of
split pin. Do not loosen the nut for inserting
the split pin.
4. Check if the splined connection and the fastening bolt between the pitman and the steering gear
rocker shaft are loose.
5. Check and adjust the meshing condition of steering gear rocker shaft and rack piston.
Inspection of Driving Axle Final Drive Oil Level
Single reduction drive axle Rear axle

Initial change
Normal inspection
Every5,000km
Check method
With the oil level access hole plug removed, the oil
level should be flush with the lower edge of access
hole, and add the oil if insufficient. Check and
clean the breather plug.
1. Breather plug 3. Rear axle oil level
Normal change access hole
2. Rear axle oil drain
Every 30,000km (in normal conditions); plug
Every 20,000km (the vehicle is under heavy load Intermediate axle
working conditions or in the environment of serious
pollution for a long time).
Replacement method
Change the transmission oil when engine is hot.
Screw off the oil drain plug to drain the oil
completely, then clean and fit it back. Add new
lubricating oil from the oil level access hole (oil filler
for intermediate axle) until the oil level is flush with
lower surface of the oil filler.
CAUTION:
1. Keep dirt or dust out of the final 1. Oil filler 3. Intermediate axle
drive when adding oil, and oil drain plug
2. Intermediate axle
always keep the breather plug in oil level access 4. Breather plug
a good condition. hole
2. Oil should be kept at a normal
level. Otherwise, the use of oil
may be affected by too high or
too low oil level.
Tyre Use and Maintenance

Selection of tyre
Vehicle model Dump truck, etc. Cargo truck and tractor, etc.
Low speed, poor road Higher speed, good road High speed, good road
Service
conditions, overload conditions,overload but conditions, overload but
Conditions
exceeding 50% not exceeding 50% not exceeding 30%
Tubeless tyre Forbidden Allowed Preferred
Meridian tyre Allowed Preferred Allowed
Not recommended
Bias tyre Preferred Forbidden
conditions
Don’t overload
Vehicle overload will increase the tyre heat-up and accelerate the wear of tyre tread, which may increase
the tyre bead stress, cause tyre bead damage and early fatigue of casing ply, and reduce the service life
of tyre.
Select proper tread patterns
Longitudinal pattern: low rolling resistance and good guiding performance
Dual-purpose and transverse pattern: high tear resistance and good driving performance
Select longitudinal pattern for guide wheels and trailer wheels; select dual-purpose and transverse
pattern for driving wheels
Vehicle
Dump truck Cargo truck Tractor
model
Position Steering axle Driving axle Steering axle Driving axle Steering axle Driving axle
Longitudinal Longitudinal
National Longitudinal pattern or Longitudinal Longitudinal Longitudinal pattern or
highway pattern dual purpose pattern pattern pattern dual purpose
pattern pattern
Longitudinal Longitudinal Longitudinal Longitudinal Longitudinal
General Off-road
grooved grooved grooved grooved grooved
pattern or
road pattern or pattern or pattern or pattern or pattern or
transverse
condition dual purpose longitudinal dual purpose dual purpose transverse
pattern
pattern pattern pattern pattern pattern
Longitudinal
Severe Transverse Off-road Off-road
grooved
pattern or pattern or pattern or
road pattern or - -
dual purpose transverse transverse
condition dual purpose
pattern pattern pattern
pattern
Replacement of tyre
Tyre specifications and relevant parameters are as follows:
Overall dimension: Bearing Standard
Tyre width* diameter * Wheel capacity, pressure,
Tyre specification
category static loaded radius/ specification single/ dual single/ dual
rolling radius (mm) tyre (kg) tyre (kPa)
12.00-20 18PR 315*1125*536/536 8.5-20 3,750/3,350 810/740
11.00-20 18PR 293*1085*517/517 8.0-20 3,650/3,150 910/840
11.00-20 16PR 293*1085*517/517 8.0-20 3,350/2,900 810/740
10.00-20 18PR 278*1055*502/502 7.5-20 3,350/2,900 910/840
Tubed tyre 10.00-20 16PR 278*1055*502/502 7.5-20 3,000/2,650 810/740
Bias tyre 9.00-20 16PR 259*1018*485/485 7.0-20 2,900/2,500 880/810
9.00-20 14PR 259*1018*485/485 7.0-20 2,575/2,300 770/700
9.00-20 12PR 259*1018*485/485 7.0-20 2,360/2,060 670/600
9.00-20 10PR 259*1018*485/485 7.0-20 2,120/1,850 560/490
8.25-20 14PR 236*974*464/464 6.5-20 2,240/1,950 810/740
12.00R20 18PR 315*1125*516/534 8.5-20 3,750/3,450 830/830
11.00R20 18PR 293*1085*499/517 8.0-20 3,550/3,250 930/930
11.00R20 16PR 293*1085*499/516 8.0-20 3,350/3,075 830/830
Tubed tyre 10.00R20 18PR 278*1054*486/502 7.5-20 3,250/3,000 930/930
Meridian
tyre 10.00R20 16PR 293*1085*499/516 8.0-20 3,350/3,075 830/830
9.00R20 16PR 259*1019*471/485 7.0-20 2,800/2,650 900/900
9.00R20 14PR 259*1019*471/485 7.0-20 2,575/2,430 790/790
8.25R20 14PR 236*974*452/464 6.5-20 2,240/2,120 830/830
13R22.5 18PR 320*1124*521 9.75*22.5 3,750/3,450 830/830
Imperial 12R22.5 18PR 300*1085*504 9.00*22.5 3,550/3,250 930/930
Tubeless 11R22.5 16PR 279*1054*491 8.25*22.5 3,000/2,725 830/830
10R22.5 14PR 254*1018*476 7.5*22.5 2,575/2,430 790/790
315/80R22.5 18PR 312*1076*500 9.00*22.5 3,750/3,450 830/830
Metric 295/80R22.5 16PR 298*1044*487 9.00*22.5 3,350/3,075 830/830
Tubeless 275/80R22.5 16PR 276*1012*473 8.25*22.5 3,075*2,800 830/830
255/80R22.5 16PR 255*930*435 7.5*22.5 2,500*2,300 830/830
The principle of tyre replacement should refer to the bearing capacity parameters. Under the equivalent
bearing capacity, the diameter of metric tubeless tyre is smaller than that of tyre with inner tube, which
can reduce the height of complete vehicle and enhance the vehicle stability.
For example: 315/80R22.5 18PR tyre can replace 12.00R20 18PR or11.00R20 18PR tyre.
Inspection of Tyre Pressure and Tread

1. Use barometer to check whether each tyre pressure meets the requirements, and inflate the tyre if
insufficient.
2. Check if there is any foreign matter attached to the tyre tread and remove it if any.
3. Check the depth of tread pattern. Replace the tyre if the depth is less than1.6mm (less than 2.4mm
on the freeway). Measure at least six points along the tyre circle.
4. The pressure in the above table is in standard conditions. The pressure should increase and the
running speed decrease when the load increases.
5. Both high pressure and low pressure will reduce the service life of tyres and increase the fuel
consumption.
6. According to the vehicle load, the average maximum inflation pressure should be 850-1250kPa.
The front wheel pressure is generally lower than the driving wheel pressure. Normally, the tyres
should be inflated every 6 months or so.
Periodical inspection of wheel alignment
Wheel alignment includes front wheel alignment and rear wheel alignment. Front wheel alignment
out-of-tolerance will result in abnormal wear of front wheels; rear wheel alignment out-of-tolerance will
not only result in abnormal wear of driving tyres, but also abnormal wear of front wheels.
Front wheel alignment mainly involves toe-in (see Page 115) and camber angle. The toe-in of the front
wheel should be within 1 -3mm and the camber angle should be within 1°± 30′.
Rear wheel alignment mainly involves rear axle offset angle θ and propulsion angle ω. When both the
rear axle offset angle and the rear axle propulsion angle are large, abnormal wear will happen to all tyres.
In the case of rear axle offset, check the rear axle leaf spring for deformation, and thrust bar joint for
wear, and replace them in time.
Tyre Transposition
During the maintenance every 10,000km, change

the positions of tyres as illustrated. Principles of
tyre transposition:
1. For rear axle twin tyres, the difference
between the outside diameters of the tyres
should not exceed 12mm and the smaller one
should be mounted inside.
2. The front wheels should be equipped with
tyres of the same model with even and less
wear. Do the dynamic balance test on the
newly changed position or assembled front
tyres where possible.
3. After transposition, the rotating direction of
tyre should be reverse to that before
transposition. The new tyres must be used in
pairs.
4. The same axle must be equipped with tyres of
the same specification and tread; otherwise,
brake deviation, vehicle body swing, and
out-of-control steering may occur.
5. Check the threads of wheel hub bolt and
wheel nut for scratches. For the sake of
safety, replace the nut and bolt in pairs if the
thread of either one has been damaged, since
the other one may be damaged as well.
6. Check the contact face (spherical face) and
mounting holes of wheel rim, if any
deformation or damage is found, replace it. If
the spherical face of tyre nut also has
damage, replace the nut.
7. Check the wheel rim and replace it if any
crack is found.
8. Separate the valve cores of inside and outside
tyres for easy inflation during installation of
twin tyres.
Requirements for wheel dynamic balance
Tyre specification Wheel assembly unbalance amount (g.cm)

12.00-20 18PR ≤ 8,000
11.00-20 18PR ≤ 8,000
10.00-20 16PR ≤ 5,000
10.00-20 18PR ≤ 5,000
9.00-20 16PR ≤ 5,000
12.00R20 18PR ≤ 8,000
12.00R24 18PR ≤ 8,000
11.00R20 18PR ≤ 8,000
10.00R20 16PR ≤ 5,000
10.00R20 18PR ≤ 5,000
9.00R20 14PR ≤ 5,000
9.00R20 16PR ≤ 5,000
8.25R16 14PR ≤ 3,000
12R22.5 18PR ≤ 5,000
315/80R22.5 18PR ≤ 5,000
295/80R22.5 16PR ≤ 5,000
295/80R22.5 18PR ≤ 5,000
275/80R22.5 16PR ≤ 3,000
235/75R17.5 16PR ≤ 3,000
315/70R22.5 18PR ≤ 5,000
255/70R22.5 16PR ≤ 5,000
245/70R19.5 16PR ≤ 5,000
Replacement and repair of wheels

When replacing the wheel, it is recommended to select the wheel supplier and model as used in the
original vehicle. It is recommended to have the tyre repaired by a professional tyre repair shop.
Adjustment of Front Wheel Alignment
Check each steering axle toe-in when doing

maintenance every 20,000km. The recommended
front wheel toe-in is 1-3mm.
Adjustment method of front wheel toe-in
1. Park the vehicle on a flat ground, jack the
front axle and keep the wheels in straight
driving position.
2. Loosen the tie rod clamp bolt and rotate the
tie rod with pipe pliers to get the required
toe-in.
3. Make a mark on the middle of the tread
pattern of left and right tyres during
adjustment and measure value B right ahead
of the front axle and then turn the mark to the
right back to measurevalue A.
4. The difference of values A and B is the toe-in.
5. After adjustment, tighten the clamp bolt to
38-42N·m.
Tyre Inflater
Tyre inflation device is a kind of equipment using

the inflation valve to take air from the air reservoir
directly.
Operation procedures are as follows:
1. Unscrew the plug of air inflation valve,
connect the tyre inflation hose with air inflation
valve and tighten the joint.
2. Start the engine to operate the air
compressor. Keep engine running at a
medium speed during the inflation.
3. After the pressure inside the air reservoir rises

to 6.5 × 100kPa, align the other end of
inflation hose with the tyre valve to inflate, and
measure the pressure with a barometer to
ensure that the tyre pressure reaches the
specified value.
4. Remove the inflation hose, tighten the air
inflation valve cap, and then stop the engine.
Maintenance of Wheel Hub Bearing

vehicle.
Conduct wheel hub bearing maintenance every
10,000km. Remove the wheel and brake drum,
clean wheel hub bearing, clean the deteriorated
lubricating grease away from the hub inner
chamber, fill gap between bearing cone and holder
roller with new grease, and apply a thin coat of
grease on the internal and external surfaces of
bearing. After that, reassemble them.
1. Wheel hub 3. Locking nut
Adjustment of front wheel hub bearing (axle
2. Friction lining
that can bear the weight more than 5T)
1. Tighten the lock nut to 200N·m and rotate the
hub for 2-3 turns to fit the bearing completely.
2. Tighten the lock nut to 200N·m.
3. It's allowed to turn the locking nut for 30°back
to insert the split pin and get the correct hub
bearing pretension force.
4. Rotate the hub 2-3turns and the measured
tangential force at hub bolt which should be
20-55N.
5. Insert the split pin for locking.
Adjustment of hub bearing (4.5T axle)

1. Fit the hub assembly first, then the friction lining and the locking nut which should be tightened
to120 -150N·m, and meanwhile, rotate the hub 2 -3 turns to fit the bearing completely, after which,
lock the locking nut by tightening it to 120 -150N·m.
2. To get the correct hub bearing pretension force, screw the locking nut back up to the required hub
rotating resistance torque.
3. Also, for the purpose of aligning the split pin hole with the slot on the locking nut, screw the locking
nut back further for 30°.
4. Finally check the hub rotating resistance torque: it should be 4.1 -8.2N·m, and the tangential force
at the hub bolt should be 30 -60N.
Adjustment of rear wheel hub bearing

1. Tighten the adjusting nut and rotate the wheel
so as to move the bearing to the correct
position.
2. Tighten the adjusting nut to 500N·m or more,
and then loosen it by 1/4 - 1/6 turn.
3. At this moment, the wheel should rotate freely
without visible axial play or swing. Fit lock
plate and fastening screw.
CAUTION:
Align the lock plate screw with the
adjusting nut until get the minimum
looseness of the adjusting nut.
Removal and Installation of Spare Wheel
Spare wheel carrier

1. Screw off the long security thread, turn the
driving rod with a wrench to lower the spare
wheel, remove the bracket and pull out the
spare wheel for use.
2. Install the spare wheel in reverse sequence.
Tighten the long locking threaded sheath
during spare wheel installation.
1. Long thread 2. Washer
Replacement of tyre
Removal of tyre
1. Block the rear wheels (front wheels) with
triangular fillets front and back to remove the
front wheels (rear wheels).
2. Unscrew the wheel nuts by the wheel nut
socket spanner in the driver’s tools.
3. Jack one end of the axle up to raise the wheel
off ground a little.
Jack up the front axle
4. Rinse the tyre bolts and nuts with clean water
and soak them in engine oil or apply grease to
them.
5. Remove the wheel nuts.
CAUTION:
1. When removing the nut, if the
threads contain silt or dirt, clear
the silt away with water or oil,
apply a little grease on the Jack up the rear wheel
exposed threads, and then
remove the nuts. This is to avoid
threads damage and locking in
case of greater removal torque.
2. To refit a nut, apply grease or oil
on it so as to guarantee screw
thread pair’s normal service and
avoid loosening or locking.
Installation of tyre
1. Fit the wheel rim bolt hole over the wheel hub
bolt by a pry bar.
2. Adjust the wheel hub bolt to the center of bolt
hole and tighten the wheel nut.
3. Lower the jack slowly to make the tyre contact
the ground.
4. Tighten the wheel nuts to 550-650N·m in
three steps diagonally.
5. After each reinstallation of wheel nuts, and
within first 200-500km or 1-2 days, retighten
the nuts to the torque of 550- 650N.m.
Inspection and Maintenance of Battery

vehicle.
Disconnect the power master switch before
inspection and maintenance of battery.
Inspection of maintenance-free battery
indicator
Inspect the status indicator, green indicates the
1. Status indicator
battery is under good status, black indicates the
battery requires to be charged, and white indicates
the battery requires to be replaced.
Inspection of electrolyte level

Check electrolyte level every 5,000km. The normal
level should be 15 -20mm above the pole plate. If
the level is low, add distilled water and then charge
the battery over half an hour, so as to mix the
added distilled water with the original electrolyte.
1. Electrolyte 2. Pole plate
Inspection of electrolyte specific weight
Check electrolyte specific weight every 10,000 km.

The normal electrolyte specific weight is within
1.28±0.01 (electrolyte temperature is 25°C), and
the battery must be recharged if the specific weight
is less than 1.23 (in winter)/1.18 (in summer).
1. Floater 3. Electrolyte level

2. Level reading
Fusible link
Confirm the load of a fuse to be used before

replacing the fuse. If the new fuse is very easy to
burn out, then find out the cause and eliminate it.
In the case of troubleshooting failure, contact the
nearest Technical Service Centre (Station)
authorized by Dongfeng Commercial Vehicle
WARNING:
Use of ordinary conducting wire or
fusible link of a different specification
for substitution is strictly prohibited.
Arrangement of Lamplight
1. Front combination lamp 4. Front marker lamp

2. Front fog lamp 5. Side turn signal lamp
3. Front end-outline marker lamp
Arrangement of cab lamplight

1. Front combination lamp: two pieces with the left one symmetrical with the right one, including the
front turn signal lamp, position lamp, high beam and high/low beam;
2. Front fog lamp: two pieces, with the left one symmetrical with the right one;
3. Front end-outline marker lamp: two pieces, with the left one symmetrical with the right one;
4. Front marker lamp: three pieces;
5. Side turn signal lamp: two pieces, with the left one symmetrical with the right one.
Front combination lamp
1. High/low beam
2. High beam
3. Position lamp
4. Front turn signal lamp
Rear combination lamp

1. Turn signal lamp lens
2. Reflex reflector
3. Reversing lamp lens
4. Rear fog lamp
5. Brake lamp
6. Position lamp
7. Side marker lamp
The left combination lamp is symmetrical with the
right one.
Light Adjusting Method

Leftward/rightward light adjusting mechanism:
clockwise rotation is for leftward adjustment and
counterclockwise rotation is for rightward
adjustment. Adjustment torque: 0.35N.m-0.5N.m.
Upward/downward light adjusting mechanism:
clockwise rotation is for upward adjustment and
counterclockwise rotation is for downward
adjustment. Adjustment torque: 0.35N.m-0.5N.m.
Preparations
1. The site for light adjustment should be flat and 1. Leftward/rightward 2. Upward/downward
the screen used should be vertical to the site. light adjusting light adjusting
mechanism mechanism
2. The vehicle should be unloaded with one
driver seated and tyre pressure kept normal.
3. The vehicle should be vertical to the screen
and the reference center of the headlamp
should be 10m away from the screen.
4. Draw a horizontal reference line on the
screen. The height of the reference line
should be the same as the 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 the
vehicle headlamp.
Adjustment of low beam lighting position
Project the low beam to the screen in accordance
with the following requirements:
Cover the right front combination lamp first to let no
beam leak out, and adjust the upward/downward
light adjusting mechanism to make the height of
the cut-off line angle or the center point of the low
beam of the leftlampbe 0.6H - 0.8H;
adjust the leftward/rightward light adjusting mechanism to make the leftward horizontal deflection of the
low beam within 170 mm and the rightward deflection within 350 mm.
After the adjustment of the left low beam, cover the left front combination lamp to let no beam leak out,
and adjust the right high/low beam to make the height of the cut-off line angle or the center point of the
low beam of the right lamp be 0.6H - 0.8H; the leftward horizontal deflection of the low beam should be
within 170mm and the rightward deflection should be within 350mm.
Adjustment of high beam lighting position
Project the high beam to the screen in accordance with the following requirements:
Cover the right front combination lamp first to let no beam leak out, and adjust the upward/downward
light adjusting mechanism to make the height of the high/low beam of the left lamp be 0.8 H-0.95 H;
adjust the leftward/rightward light adjusting mechanism to make the leftward horizontal deflection of the
high beam within 170mm and the rightward deflection within 350mm. The adjusting method for the single
high beam of the left lamp is the same as that for high/low beam.
After the adjustment of the left high beam, cover the left front combination lamp first to let no beam leak
out, and adjust the right high/low beam to make the height of the high beam of the right lamp be 0.8
H-0.95 H; both the leftward horizontal and rightward deflection of the high beam should be within 350mm.
The adjusting method for the single high beam of the right lamp is the same as the method above.
Beam of left high beam headlamp Beam of right high beam

Leftward headlamp Leftward Beam of right low beam headlamp
deflection
Rightward Leftward deflection
Beam of left low beam headlamp
deflection and Rightward
rightward deflection
Leftward Refere
deflection
deflection
Rightward nce
deflection line
Vehicle lamp ground

clearance
Beam cut-off line High beam

angle of low beam Light measurement
Beam center (brightest point)
headlamp screen
Auxiliary Power Starting

Frame ground
Master power
switch
a) Dead battery b) Live battery
1. Negative power cord 4. Booster cable (black)

2. Positive power cord 5. Starter power
3. Booster cable (red)
In case the battery is discharged and the engine cannot be started, start the vehicle by auxiliary power.
The connecting procedures are as follows:
1. Shut down the engine of the vehicle equipped with a well charged battery.
2. Connect one end of the booster cable (red) to the positive terminal of the dead battery, and the other
end to the positive terminal of the live battery. Connect one end of another booster cable (black) to
the negative terminal of the well charged battery, and the other end to the chassis frame of the
vehicle equipped with dead battery and keep it far from the battery.
3. After connecting the booster cables, start the engine of the vehicle equipped with the dead battery.
4. After the engine being started, remove the cables in the procedures reverse to the wiring
procedures.
CAUTION:
1. This way can be used in emergency only because it is liable to cause fuse burning
of charging circuit. Under normal conditions, dismount the battery to charge it
when the battery is out of power.
2. Prevent power short circuit during removal and refitting of booster cable.
3. Failing to observe the above rules in the event of auxiliary power starting may
damage the vehicle electronic devices.
4. Do not start the vehicle with the battery of 36 V, 48 V or higher voltage in any case;
otherwise, these batteries will damage electronic devices directly. The driver and
service staff must observe this rule.
Maintenance of Cab Lifting Device

vehicle.
Single-cylinder, manual and semi-floating type
& single-cylinder, manual and full-floating type
1. Air plug (oil filler)
2. Rocker arm
3. Oil tank
4. Reversing handle
5. Pipe joint
6. Seat spring plug (M12X1.5 screw at the bttom
of cylinder)
7. Pipe joint
Making the reversing handle face upward can tilt

the cab upward and inclining (clockwise rotation) it
can tilt the cab downward. The oil tank has the
relevant signs. The reversing handle should be in
lowering (inclination) position (to achieve the
follow-up function of cylinder) when the vehicle is
out of service and during vehicle running. When
the cab is to tilt beyond the gravity centre, slow
down the oil pumping speed, and try to have the
cab tilt to position under its own weight as much as
possible to reduce the impact upon cab tilting at
proper position.
Sticker signs of A and B are provided at the pipe
joints of the cylinder and oil pump respectively.
Connection of oil pipes: the pump port A
corresponds to the cylinder port A, the pump port B
corresponds to the cylinder port B. Do not
connect the oil pipes wrongly upon reconnection of
the cylinder and oil pump pipes after the removal;
otherwise, the cab will rise only.
The oil pump employs J15 shock absorber oil with the condensation point of -55°C, and the oil can be
used in any region and season.
Generally, 32# or 46# hydraulic oil with the condensation point of -6°C can be used. Take special care
when such oil is used in cold area.
Before filling the tank with the oil, set a filter screen of 100-mesh at the tank port so as to prevent impurity
into the system as well as system failure. The hydraulic oil should be changed once a year.
Degenerative hydraulic oil is liable to cause system failure.
Single-cylinder, electric and full-floating type

2. Rocker arm
3. Oil tank
4. Reversing handle
5. Pipe joint
6. Motor
7. Pipe joint
8. Four-hole connector
10. Three-hole connector
11. (Touch) button
12. Seat spring plug
13. Pipe joint

the cab is to tilt beyond the gravity center, slow
proper position.
Sticker signs of A, B and E are provided at the pipe

joints of the cylinder and oil pump respectively.
Connection of oil pipes: the pump port A
corresponds to the cylinder port A, the pump port B
corresponds to the cylinder port B, and the hand
pump port E corresponds to the electric cylinder
port E. Do not connect the oil pipes wrongly upon
reconnection of the cylinder and oil pump pipes
after the removal; otherwise, the cab will rise only.
As for the cab lifting controller, the four-hole
connector connects the electric pump, and the
three-hole connector connects the chassis wire
harness.
The oil pump employs J15 shock absorber oil with
the condensation point of -55°C, and the oil can be
Generally, 32# or 46# hydraulic oil with the
condensation point of -6°C can be used. Take
special care when such oil is used in cold area.
Before filling the tank with the oil, set a filter screen
of 100-mesh at the tank port so as to prevent
impurity into the system as well as system failure.
The hydraulic oil should be changed once a year.
Degenerative hydraulic oil is liable to cause system
failure.
Full-floating electric lifting device with double-cylinder

2. Rocker arm
3. Oil tank
4. Reversing handle
5. Pipe joint
6. Motor
7. Pipe joint
10. Three-hole connector
11. (Touch) button
12. Pipe joint
13. Seat spring plug
14. Pipe joint
the cab is to tilt beyond the gravity center, slow
proper position.
Sticker signs of A, B, D and E are provided at the

pipe joints of the cylinder and oil pump
respectively. Connection of oil pipes: the pump
port A corresponds to the right cylinder port A, the
pump port B corresponds to the right cylinder port
B, the hand pump port E corresponds to the
electric pump port E; the right cylinder port D
corresponds to the left cylinder port D, and the
right cylinder port B corresponds to the left cylinder
port B. Do not connect the oil pipes wrongly upon
reconnection of the cylinder and oil pump pipes
after the removal; otherwise, the cab will rise only.
As for the cab lifting controller, the four-hole
connector connects the electric pump, and the
three-hole connector connects the chassis wire
harness.
The oil pump employs J15 shock absorber oil with
the condensation point of -55°C, and the oil can be
Generally, 32# or 46# hydraulic oil with the
condensation point of -6°C can be used. Take
special care when such oil is used in cold area.
Before filling the tank with the oil, set a filter screen
of 100-mesh at the tank port so as to prevent
impurity into the system as well as system failure.
The hydraulic oil should be changed once a year.
Degenerative hydraulic oil is liable to cause system
failure.
Oil Filling Volume for Cab Tilting Pump
Perform quantitative oil filling by dedicated filling
equipment according to the following
requirements:
Semi-floating single-cylinder lifting system: one-off
filling of 480-500 ml;
Full-floating single-cylinder lifting system: one-off
filling of 600-620 ml;
Double-cylinder lifting system: fill oil in two steps.
Fill up to 680-700 ml for the first time; and up to
400-420 ml for the second time after cab tilting is
made to start the cab.
Regular Maintenance Schedule

The regular maintenance schedule in this manual is a general schedule. Refer to the specific model
configurations when using it. For the disassembly items of large assemblies, conduct it according to the
specific conditions to maintain the technical state of the vehicle.
Please refer to the attached Operation and Maintenance Manual of Cummins Engine for the
maintenance schedule.
Inspection and Maintenance Term
This maintenance schedule shows the inspection and maintenance items and term of the first cycle; for
the second cycle, the maintenance items are the same except the running-in maintenance is not
required. The inspection and maintenance term is expressed in the driving mileage and/or months
whichever comes first . The user should carry out the maintenance according to the maintenance parts
and interval mileage or months strictly.
CAUTION:
When performing the vehicle maintenance in accordance with the specified
maintenance items, the user should shorten the maintenance interval mileage and add
the required maintenance items according to the vehicle functions and local operating
condition, to ensure more reasonable maintenance and better performance of your
vehicle, however, the user should never extend the maintenance interval mileage.
The meanings of symbols in the maintenance schedule are as follows:

1. A indicates total driving mileage (×1,000 km).
2. B indicates the month.
3. ★ indicates normal running maintenance items.
4. ☆ indicates running-in maintenance items.
5. △ indicates running-in maintenance mileage (1,500 - 2,500 km).
Engine (Cummins B Series)
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 engine assembly ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check and adjust belt tension ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check coolant for leakage ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check engine for oil leakage ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check lubricating oil for cleanness and oil
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
level
Check fuel for leakage ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Engine (Cummins B Series)
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
Remove sediment in fuel filter ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check accelerating and decelerating
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
performance as well as exhaust condition
Check and clean air filter element ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Change engine oil ★ ★ ★ ★ ★ ★
Replace oil filter assembly ★ ★ ★ ★ ★ ★
Replace fuel filter and oil water separator ★ ★ ★
Replace primary fuel filter ★ ★ ★
Check and adjust air valve clearance ☆ ★ ★ ★
Tighten cylinder head and bolts ★
Replace air filter element ★ ★
Check whether radiator works normally ★
Check the functions of thermostat ★
Clean engine cooling system ★
Check fuel injector for injection pressure
★
and timing
Check whether fuel feed pump works
★
normally
Check cylinder compression pressure ★
Engine 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 lubricating oil, fuel and coolant for
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
leakage
Check level of lubricating oil and coolant
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
and fill fluid if insufficient
Drain water and sediment from fuel
primary filter (oil-water separator) ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
(weekly)
Check and tighten engine front and rear
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
suspension bolts
Check and clean air filter element ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check and tighten fan ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Engine 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 and tighten flexible cowl hoop ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Clean, check and tighten intake system ★ ★ ★ ★ ★ ★
Replace fuel primary filter (oil-water
★ ★ ★
separator)
Replace air filter element (subject to the
★ ★
maintenance inspection results)
Check radiator and intercooler for
★
leakage, damage and dirt accumulation
CAUTION:
1. If the warning signal appears before the inspection and replacement cycle or the
operating conditions of engine are severe, clean and replace the relevant parts in
time or shorten the maintenance interval properly.
2. After driving on the normal road for each 5,000 km (or 4,000km in the dusty region)
or when the air filter clog alarm lamp goes on, the air filter element should be
maintained. Generally, only the outer filter element can be cleaned, and the inner
element cannot be maintained but only replaced. Under normal operating
conditions, the inner and outer filter elements must be replaced at the same time
upon 30,000 km traveling or when the main filter element has been cleaned and
maintained for 5 times or more.
3. Clean the engine cooling system, and change the engine coolant every 2 years
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 working conditions of clutch
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
(including clutch pedal free stroke)
Check clutch hydraulic system, master
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
cylinder and booster for oil leakage
Check hydraulic fluid level in clutch fluid
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
reservoir and add fluid if insufficient
Change clutch hydraulic oil ★
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
Clean transmission and breather plug ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check transmission for oil leakage ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check transmission fluid level and fill
☆ ★ ★ ★ ★ ★ ★
fluid if required
Check control mechanism for malfunction
☆ ★ ★ ★
or breakage
Change transmission fluid ☆ ★ ★
1
Change transmission fluid ☆ ★ ★ ★
Replace transmission oil filter
☆ ★
(if equipped)
Check working conditions of transmission
★
bearings
1
It is recommended in case the vehicle operates under heavy load or in an environment with
severe pollution for a long term.
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 free travel of brake pedal ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check service and parking brake
efficiency; check and adjust brake ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
clearance as required
Check and eliminate air leakage of brake
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
air pipeline and elements (valves)
Check and tighten brake bottom plate;
check wear conditions of brake drum and ☆ ★ ★
friction lining
Check reverse adjustment torque of
★ ★ ★
automatic adjuster (if equipped)
Replace air dryer drum or desiccant ★ ★
Check water in the air reservoir and air
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
dryer (weekly)
Brake pad wears (disc brake) ☆ ★ ★ ★ ★ ★ ★
Brake disc wears (disc brake) ☆ ★ ★ ★ ★ ★ ★
Brake System
Check brake disc for crack (disc brake) ☆ ★ ★ ★ ★ ★ ★

Check dust covers for damage ☆ ★ ★ ★ ★ ★ ★
Check brake caliper for sliding function (disc
☆ ★ ★
brake)
Clearance self-regulation (disc brake) ☆ ★ ★
Check position lever for travel (disc brake) ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
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 steering system for leakage ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check free travel and operation of
steering wheel (including connection of
steering system components, connection
of steering tie rod and drag link ball joints, ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
fastening of steering gear and support,
fastening of steering knuckle arm and
pitman)
Check oil level of power steering fluid
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
reservoir and add oil if insufficient
Check and adjust front wheel toe-in ☆ ★ ★ ★
Change steering hydraulic oil and oil
☆ ★ ★ ★
reservoir filter element
Check rear wheel alignment ☆ ★ ★ ★
Check whether hydraulic oil pump works
★
normally
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
Clean and check leaf spring, and fasten
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
U-bolts
Tighten leaf spring U-bolts under full load ☆ ★ ★ ★ ★ ★ ★
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
Clean and check shock absorber
(including checking shock absorber for ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
damage, looseness and leakage etc.)
Check air suspension (including checking
and cleaning air spring bellow, checking
air spring assembly conditions, system ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
exterior stoppers and position of height
sensor) (if equipped)
Check spring clamp for looseness and
★ ★ ★ ★ ★ ★
deformation
Check lubricating oil level of balance
bearing hub (if equipped), and add if ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
insufficient
Change lubricating oil of balance bearing
☆ ★ ★ ★ ★ ★ ★
hub (if equipped)
Propeller 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 propeller shaft (including checking
connections and cross spider bearings
for looseness and offset, and checking ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
propeller shaft intermediate support for
looseness)
Check propeller shaft spline for wear ★
Axle and Wheel
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
Clean driving axle breather plug ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Check driving axle oil level, and add oil if
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
insufficient
Check and fasten wheel assembly
(including checking fastening of axle
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
shaft bolts and wheel nuts, checking tyre
pressure and abnormal wear and etc.)
Check wheel rim assembly for damage
★ ★ ★ ★ ★ ★
and deformation
Axle and Wheel
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 and adjust hub bearing clearance
★ ★ ★ ★ ★ ★
and do lubrication
Do tyre transposition ★ ★ ★ ★ ★ ★
Adjust clearance of ABS sensor and clean
★ ★ ★ ★ ★ ★
it (if equipped)
Change driving axle final drive lubricating
oil (single reduction drive axle) (if ☆ ★ ★
equipped)
Change lubricating oil for rear axle final
drive ☆ ★ ★ ★
(Single reduction drive axle)1
Change driving axle final drive lubricating
oil (double reduction drive axle) (if ☆ ★
equipped)
Change lubricating oil for rear axle final
drive ☆ ★ ★ ★
(double reduction drive axle)1
Check rear axle final drive and bearing ★
1
It is recommended in case the vehicle operates under heavy load or in an environment with
severe pollution for a long term.
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 and clean EECU interface (only
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
for electronically controlled engine)
Read and delete EECU fault code (only
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
for electronically controlled engine)
Check battery electrolyte level and add
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
electrolyte if insufficient
Check connection and fixation of
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
electrical circuit
Check electrical component function
(including lamp, switch, instrument, ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
wiper, heater, A/C, starter etc.)
Check alternator efficiency ☆ ★ ★ ★ ★ ★ ★
Check battery electrolyte specific weight ★ ★ ★ ★ ★ ★
Miscellaneous
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 cab connections and frame rivets
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
for looseness
Check hydraulic system for leakage and
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
air tightness
Check cab (front) rear suspension shock
absorber for leakage, damage and ★ ★ ★
looseness and replace it if necessary
Check condition of cab front suspension
rubber sleeve assembly and replace it if ★ ★
necessary
Check condition of cab front (rear)
suspension spring assembly, and replace ★ ★
it if necessary
Change hydraulic oil of cab lifting device ★ ★
Regular Renewal Part

Regular renewal part means the part whose service performance will certainly decrease over 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 power steering hydraulic
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
system
Rubber parts of brake system valves ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Rubber hoses of brake system ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Rubber cup and sealing ring of brake chamber ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Rubber hose of air compressor ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Rubber hose of clutch control system ★ ★ ★ ★ ★ ★
Rubber sealing ring of clutch master cylinder ★ ★ ★ ★ ★ ★
Fuel hose ★ ★ ★ ★ ★ ★
All oil pipes of hydraulic lifting system ★ ★ ★ ★ ★ ★
Seals of cab lifting device ★ ★ ★ ★
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 refit the nipple cap if any. The
following table shows the maintenance and lubrication in the first mileage cycle, and the subsequent
maintenance should be performed according to the mileage interval or year shown in this table.
The meanings of symbols in the table are as follows:
1. A indicates total driving mileage (×1,000 km).
2. B indicates the month.
3. ★ indicates normal running maintenance items.
4. ☆ indicates running-in maintenance items.
5. △ indicates running-in maintenance mileage (1,500 - 2,500 km).
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
Clutch release system ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Steering tie rod and drag link ball pins ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Steering knuckle kingpin ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Steering propeller shaft sliding yoke and
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
cross spider bearing
Front and rear leaf spring shackle pins
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
and support pins
Propeller shaft intermediate support ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Propeller shaft sliding yoke and cross
☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
spider bearing
Front and rear brake adjusters ☆ ★ ★ ★ ★ ★ ★
Automatic adjuster ★ ★ ★ ★ ★ ★
Balance bearing hub ★ ★ ★ ★ ★ ★
Driving axle ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Wheel hub bearing ★ ★ ★ ★ ★ ★
Cab tilt locking mechanism ☆ ★ ★ ★ ★ ★ ★
Door hinge ☆ ★ ★
Alternator bearing ★
Starter bearing ★
Door lock, window regulator, odometer
★
flexible shafts
Service and Adjustment Data

Engine
Please refer to the attached Operation and Maintenance Manual of Cummins Engine for the engine.
Chassis
Free stroke of steering wheel 15°
Toe-in 1 - 3 mm
Clutch pedal travel 184 - 192 mm
Booster push rod travel after clutch exhaust (Shaanchi/ZF
22 - 27 mm
transmission of 8, 9 gears or more, pull-type clutch)
Booster push rod travel after clutch exhaust (Shaanchi/ZF
transmission/Dongfeng transmission of 8, 9 gears or more, 25 - 29 mm
push-type clutch)
Booster push rod travel after clutch exhaust (Datong transmission of
20 - 24 mm
8, 9 gears or more, pull-type clutch)
Booster push rod travel after clutch exhaust (Datong transmission of
19 - 26 mm
8, 9 gears or more, push-type clutch)
Free travel of brake pedal 12 - 18 mm
Auto adjuster 25 - 45 mm
Push rod stroke of front and rear brake chambers
Manual adjuster 20 - 30 mm
Clearance between front/rear brake shoe and brake drum (in the Auto adjuster 0.6 - 1.0mm
middle of brake shoe) Manual adjuster 0.3 - 0.5 mm
Tensile force after adjustment of front hub bearing (at the tyre nut) 25 - 55 N
Tensile force after adjustment of rear hub bearing (at the tyre nut) 29 - 88 N
Differential bearing
pre-tightening load (excluding
At driven gear bolt 68 - 78 N
pre-tightening load of driving
bevel gear bearing)
Pre-tightening load of driving Exclude oil seal resistance 20 - 44 N
gear bearing (at coupling
flange bolt holes for rear axle) Include oil seal resistance 30 - 60 N
Clearance between driving and driven gears of final drive 0.3 - 0.4 mm
Dongfeng 460 axle 0.25 - 0.33 mm
Dongfeng 435 axle 0.25 - 0.33 mm
Differential gear clearance
Dongfeng 300 wheel-side reducer 0.18 - 0.23mm
Dongfeng 500 axle 0.25 - 0.45mm
Forward and backward adjustment distance of steering wheel 80 mm
Upward and downward adjustment distance of steering wheel 50 mm
Tightening Torque
Please refer to the attached Operation and Maintenance Manual of Cummins Engine for the relevant
data.
Tightening torques of critical parts of chassis (applicable for D530 models)
CAUTION:
This standard provides the tightening torques of critical parts of vehicles manufactured
by Dongfeng Motor Co., Ltd. and is applicable for the critical parts’ threaded fasteners
for which the tightening torque is not given in the vehicle product diagram and the
technical specifications.
Tightening position Tightening torque (N⋅m)

Tightening torques of critical parts of engine mounting
Reference tightening
Bolted position Thread specification Remarks
torque (N⋅m)
Fastening bolt M14 150 - 210 -
between front/rear
mounting bracket M12 90 - 130 -
and frame
If the double nuts
280 - 350 (the first nut are adopted and
Mounting bolts M18 torque is 250 - 310 in one nut is thin, then
between engine case of double nuts) the thin nut shall be
front/rear suspension installed first.
cushion and auxiliary M14 100 - 130 -
suspension cushion
M12 70 - 100 -
M10 40 - 60 -

M14 150 - 210 -
M12 90 - 130 -
M16 (fastening bolts of DCI11
flywheel housing and left and 166 - 224 -
right arms)
Fastening bolts of
Fastening bolts of flywheel housing
engine and front and rear suspension
suspension bracket shall be
bracket/flywheel tightened by lock
housing and rear washers
suspension bracket 10ZB3-01026.
M18 320 - 420 During installation,
ensure that the bent
edge for locking the
flywheel housing is
close to the bent
edge for tilting and
locking the bolt
head.
Fastening bolts of M10 40 - 60 -
auxiliary suspension M12 90 - 130 -
cushion block to
vehicle frame M14 150 - 210 -
M14 (aluminium case) 110 - 140 -
Fastening bolts of M14 (cast steel/iron case) 150 - 210 -
auxiliary suspension
M16 175 - 235 -
cover plate and
transmission M16 stud, first nut (inside) 130 - 160 -
M16 stud, second nut (outside) 190 - 260 -

Tightening torque of critical parts of cooling and inter-cooling systems
torque
M08 (Grade 8.8) 20 - 26 -
Fastening bolts of M08 (Grade 10.9) 25 - 30 -
fan assembly flange
and engine M12 (Grade 8.8) 65 - 75 -
M12 (Grade 10.9) 90 - 110 -
fan and fan damping
block M10 (Grade 10.9) 45 - 55 -
fan flange and fan
damping block M12 (Grade 10.9) 90 - 110 -
M12 (Grade 8.8) 65 - 75 -
brace and engine M10 (Grade 8.8) 38 - 50 -
M10 (Grade 10.9) 45 - 55 -
M08 (Grade 8.8) 20 - 26 -
brace and air
deflector M10 (Grade 8.8) 38 - 50 -
M10 (Grade 10.9) 45 - 55 -
Tightening torques of critical parts of transmission system
torque

M10 (Grade 8.8) Non-flange The tightening
40 - 60
bolt method shall refer
Connecting stud
to Specifications for
bolts of clutch
Installation and
pressure plate & cap
M10 (Grade 10.9) Non-flange Adjustment of Φ430
assembly and 55 - 75
bolt Pull-type Clutch
engine flywheel
Assembly and
Control System.
M10 (Grade 8.8) Non-flange
40 - 60
bolt Firstly pre-tighten
Connecting bolts of
them crosswise and
clutch housing and M10 (Grade 10.9) Non-flange
55 - 75 then tighten them
flywheel housing bolt
with torque spanner.
M10 (Grade 10.9) Flange bolt 55 - 75
M10 50 - 70 Firstly pre-tighten
M12 100 - 120 them crosswise and
then tighten them
M14 140 - 180 with torque spanner
Connecting bolts of
(after road test,
propeller shaft
tightening torque
(including connection
shall not drop more
with transmission
than 10%;
and axle) M16 210 - 280 otherwise,
re-tighten them to
the specified
torques).
Connecting bolts of M12 (Grade 8.8) 70 - 100 -
propeller shaft cross
M12 (Grade 10.9) 90 - 130 -
member and
intermediate support M14 150 - 210 -
bracket/of propeller
shaft intermediate M16 210 - 280 -
support and bracket
Tightening torque of critical parts of vehicle frame
torque

M12 90 - 130 -
D310/D530 first
M14 150 - 210 -
cross member
M16 210 - 280 -
Tightening torques of critical parts of suspension system
torque
M27 (29Z33-04133) 860 – 1,000
M24 450 - 500 Unless otherwise
specified, all the
M22 400 - 450 U-bolts of front
U-bolts and nuts
M20 350 - 400 suspension shall be
Grade 8.8 fine-pitch
M18 280 - 350 bolt.
M16 220 - 280
M14 (Grade 8.8) 96 - 126 -
M14 (Grade 10.9, coarse pitch) 140 - 180 -
M14 (Grade 10.9, fine pitch)/
Leaf spring bracket 150 - 210 -
M14 (flange)
M12 (flange) 95 - 130 -

M18 (Grade 8.8) 280 - 350 -
M18 (Grade 10.9) 320 - 420 -
Connecting nuts of M18 (flange) 350 - 470 -
balance shaft
M20 (Grade 8.8) 350 - 450 -
support and vehicle
frame M20 (Grade 10.9, coarse pitch) 430 - 490 -
M20 (Grade 10.9, fine pitch) 430 - 550 -
M20 (flange) 490 - 670 -
M20 (Grade 8.8) 350 - 450 -
Connecting bolts of
upper and lower
thrust rods and axle M20 (Grade 10.9, fine pitch) 430 - 550 -
upper thrust rod
M18 (Grade 8.8) 280 - 350 -
bracket
M18 (Grade 10.9) 320 - 420 -
Tightening torque of critical parts of wheel
torque
Central hole
Wheel bolts 31F58-* 550 - 650
locating
Tightening torques of critical parts of steering system
Bolted position Thread specification Reference tightening torque (N⋅m)
Steering gear and its M16 210 - 280
bracket M18 320 - 420
Follower bracket and M20 380 - 500
follower fixing bolt M22 440 - 560

34Z63-01011 (M36) 400 - 550
34Z61-02011 (M42) 400 - 550
Steering M45 400 - 550
pitman/intermediate
pitman M16 210 - 260
M18 320 - 420
34N-01012 (M20) 380 - 500
All the lever ball pin nuts shall be tightened to 250 - 310 N·m firstly, and then
Lever ball pin nut
fitted with the split pin. Never loosen the nut when aligning the pin holes.
Tightening torques of critical parts of electrical system
M6 5.5 - 6.5
Alternator
M8 6.4 - 9.6
Starter power
M10 13.5 - 15.8
terminal
Starter control
M5 2 - 2.5
terminal
Auxiliary start switch M6 6 - 10
Air filter clog sensor M6 6 - 10
Fuel level sensor M5 2 - 2.5
Rear combination
M8 19 - 24
lamp
The double nuts are used for locking; the
Battery trimming
M8 tightening torque of the first nut is 7 - 9 N⋅m,
strip
and that of the second nut is 19 - 24 N⋅m.
Master power switch
M8 19 - 24
connector

Chassis ground point M8 19 - 24
Tightening torque of critical parts of cab
Steering wheel M20 130 - 150
55 - 75 (coarse pitch, Grade10.9, for matching
M10 Spiralock nuts, position: rear suspension
upper bracket)
M14 144 - 175 (coarse pitch, Grade 10.9)
D530 vehicle body 60 - 80 (coarse pitch, Grade 10.9, front
and suspension suspension upper bracket),
connecting parts M12 85 - 115 (coarse pitch, Grade 85),
10.9 - 120 (fine pitch, Grade 10.9)
90 - 120 (fine pitch, Grade 10.9)
210 - 280 (coarse pitch, Grade 10.9)
M16
220 - 300 (fine pitch, Grade 10.9)
Tightening torques of other parts of chassis (applicable for D530 models)

Disc brake and steering connecting bolts (for
385 - 415
vehicle equipped with disc brake)
Bulb
Position Model
High beam H1 (70W)
High/low beam H4 (75W/70W)
Front turn signal lamp P21W
Position lamp W5W
Front fog lamp H3 (70W)
Side turn signal lamp PY21W
Steering foot lamp P21W
Step lamp W5W
Front end-outline marker lamp R5W
Front marker lamp R5W
Cab dome lamp R10W
Cab dome lamp (fluorescent lamp) TLD18W/865
Front reading lamp C5W
Side reading lamp 13,854 (10W)
Berth reading lamp R10W
Alarm indicator lamp LED
Combination instrument
Instrument illuminating lamp LED
Rear end-outline marker lamp R5W
Turn signal lamp P21W
Brake lamp P21W
Rear combination lamp License plate lamp R5W
Position lamp R5W
Rear fog lamp P21W
Reversing lamp P21W
Side marker lamp R5W
Service lamp R10W
Capacity Data
Oiled position Grease designation Filling volume (L)
CH-4 diesel engine oil or DFL-L20 engine
12.3 - 14.2 (for oil sump
Cummins L series engine oil for Dongfeng commercial vehicle (China
only)
III engine)
Light diesel fuel conforming to national
Fuel tank 160 or 200
standard
7.5 (Dongfeng 6-speed)
Transmission 85W/90 MT-1 medium duty vehicle gear oil
9 (Datong 6-speed)
13 L for Dongfeng 9T
welding axle (for reference
90# heavy-duty vehicle gear oil (Grade
(Intermediate) rear axle only, take the oil added to
GL-5)
the lower edge of level
sight hole as the standard)
Power steering gear Engine oil of same viscosity grade 3.3
Clutch fluid reservoir V-3 hydraulic clutch system brake fluid 1.0
Cooling system DF series long life anti-freeze fluid 25
Semi-floating
single-cylinder lifting 0.48 - 0.5
system
J15 shock Full-floating
Cab tilting pump single-cylinder lifting 0.6 - 0.62
absorber oil
system
Double-cylinder lifting First filling: 0.68 - 0.7;
system Second filling: 0.4 - 0.42.
CAUTION:
1. Please refer to the attached Operation and Maintenance Manual of Cummins Engine for the
filling amount of engine lubricating oil.
Designation and service environment of oil, grease and fluid recommended by Dongfeng
Commercial Vehicle Company
Fuel designation
Fuel designation and
service environment of In areas with ambient In areas with ambient In areas with ambient
filling part temperature more than temperature more than temperature more than
-20°C -30°C -40°C
Cummins
CF-4 CF-4
Engine engine CF-4 15W-40
5W-40 (or 5W-30) 0W-40 (or 0W-30)
(China III)
Fuel 0# or -10# automotive 20# automotive diesel 35# automotive diesel
China III
tank diesel fuel fuel fuel
DF series anti-freeze DF series anti-freeze DF series anti-freeze
Coolant fluid fluid fluid
(-20#) (-30#) (-40#)
Transmission MT-1 85W-90 MT-1 80W-90 MT-1 75W-90
Driving axle GL-5 85W-90 GL-5 80W-90 GL-5 75W-90
Power steering gear ATF II D automatic transmission fluid or engine oil of the same viscosity
Clutch Chassis and wheel hub
Chassis and wheel hub General automobile lithium-based grease
Shock absorber & cab
J 15 (L-HV 15) J 15 (L-HV 15) J 15 (L-HS 15)
lifter
Dump truck lifting
L-HM 32 or L-HM 46 L-HV 32 L-HS 32
device
FQ-1 detergent for FQ-1 detergent for FQ-1 detergent for
Windshield
windshield (-20#) windshield (-35#) windshield (-40#)
Oil Products and Grease

Engine lubricating oil (Cummins engine)
Please select the oil specified by our company based on local climate and take care of the oil change
mileage. Please refer to the attached Operation and Maintenance Manual of Cummins Engine.
Designated Product
Genuine Dongfeng spare parts

Dongfeng Commercial Vehicle
(Special oil for Dongfeng
vehicles)
Steering gear lubricating oil
CF-4 diesel engine oil (China III engine) can be

used and the users can choose the oil of different
viscosity grades according to the local atmospheric
temperature. The recommended operating
temperature range is as shown:
Designated Product

vehicles)
Transmission lubricating oil
85W/90 manual transmission fluid is used for the

transmission and the users can choose the MT-1
manual transmission fluid of different viscosity
grades according to the local atmospheric
temperature.
Designated Product

vehicles)
Fuel
Only use the light diesel fuel conforming to national standards, and the user can choose different grades
of diesel fuel according to the local atmospheric temperature. Recommended temperature ranges are as
shown:
Fuel
5# 0# -10# -20# -35# -50#
designation
Applicable
ambient
temperature ≥8°C ≥4°C ≥-5°C ≥-14°C ≥-29°C ≥-44°C
(atmospheric
temperature)
Rear axle lubricating oil
It is recommended to use sulfur-phosphorous type heavy-duty (GL-5) gear oil for rear axle, and the
users can select gear oil above GL-5 of different viscosity grades based on the local atmospheric
temperature.
Designated Product

vehicles)
Oil of cab lifting device

The oil pump employs J15 shock absorber oil with the condensation point of -55°C, and the oil can be
used in any region and season. Generally, 32# or 46# hydraulic oil with the condensation point of -6°C
can be used. Take special care when such oil is used in cold area.
Lubricating grease
It is recommended to use automobile general-purpose lithium base grease for hubs and points to be
lubricated.
Designated Product

vehicles)
Clutch booster fluid
Designated Product

vehicles)
WARNING:
1. Mixing of brake fluids produced by different manufacturers is prohibited strictly.
2. Mixing of brake fluids of different types from the same manufacturer is also
prohibited strictly.
Engine coolant
Always make use of special anti-freeze and anti-rust fluid for engine. Never apply any hard water from
well or river.
DF series long life anti-freeze and anti-rust fluid is specified for Dongfeng vehicles for a long-term use.
Designated Product Dongfeng brand Dongfeng Motor Oil Product Co., Ltd.
Dongfeng Motor Lubricating Oil Co., Ltd.
WARNING:
1. The freezing point of anti-freeze liquid used in extremely cold regions shall be 10℃
lower than the local minimum ambient temperature.
2. Do not mix anti-freeze or anti-rust liquid of different grades.
Windshield cleaner
Use the automobile windshield detergent produced by Xiangfan Tongyi Petroleum Chemical Co., Ltd.
Technical Parameters
Mass parameters
Mass parameters (kg) DFL1120B chassis DFL1120B1 chassis
Kerb mass 4,600 4,450
Total mass 12,495 12,490
Mass parameters (kg) DFL1120B2 chassis DFL5120XXYB1 chassis

Kerb mass 4,550 4,850
Total mass 12,490 12,495
Mass parameters (kg) DFL1120B complete vehicle DFL1120B1 complete vehicle

Kerb mass 5,880 6,110, 5,850
Total mass 12,005 12,000
Rated loading mass 5,930 5,695, 5,955
DFL5120XXYBXX1 complete
Mass parameters (kg) DFL1120B2 complete vehicle
vehicle
Kerb mass 5,950 6,205
Total mass 12,105 12,100
Rated loading mass 5,960 5,700
Dimension Parameters
DFL1120B chassis DFL1120B1 chassis
(mm)
Total length (mm) 8,790, 8,290 7,090, 6,400
Total height (mm) 2,760, 3,400 2,760
Total width (mm) 2,370 2,370
Wheelbase (mm) 5,000, 4,700 3,800, 3,650
Front
1,880 1,880
Track width wheel
(mm) Rear
1,800, 1,860 1,800, 1,860
wheel
Front
1,430 1,430
Overhang overhang
(mm) Rear
2,360, 2,160 1,860, 1,320
overhang
DFL1120B2 chassis DFL5120XXYB1 chassis
(mm)
Total length (mm) 7,790, 7,490, 7,290, 6,990 9,790
Total height (mm) 2,760 2,760, 3,400
Wheelbase (mm) 4,500, 4,200 5,600
Front
1,880 1,880
Track width wheel
(mm) Rear
1,800, 1,860 1,800, 1,860
wheel
Front
1,430 1,430
Overhang overhang
(mm) Rear
1,860, 1,360 2,760
overhang
DFL1120B complete vehicle DFL1120B1 complete vehicle
(mm)
Total length (mm) 9,000, 8,600, 8,500 7,300, 7,000
Total height (mm) 2,830 2,870
Wheelbase (mm) 5,000, 4,700 3,800, 3,650
L 6,600, 6,200, 6,100 4,800, 4,500
Carriage
internal W 2,294, 2,400 2,294
dimension
H 600 600
Front
1,880 1,880
Track width wheel
(mm) Rear
1,800, 1,860 1,800, 1,860
wheel
Front
1,430 1,430
Overhang overhang
(mm) Rear
2,570, 2,470, 2,370 2,070, 1,920
overhang
Dimension Parameters DFL5120XXYBXX1 complete

DFL1120B2 complete vehicle
(mm) vehicle
Total length (mm) 8,000, 7,700 9,995
Total height (mm) 2,870 3,760
Wheelbase (mm) 4,500, 4,200 5,600
Length 5,600, 5,300 7,500
Carriage
internal Width 2,294 2,400
dimension
Height 600 2,400
Front
1,880 1,880
Track width wheel
(mm) Rear
1,800, 1,860 1,800, 1,860
wheel
Front
1,430 1,430
Overhang overhang
(mm) Rear
2,070 2,965
overhang
Performance Parameters
Performance parameters DFL1120B chassis DFL1120B1 chassis
Max. vehicle speed (km/h) 90, 110 (speed limit: 80)
Max. gradeability (%) ≥ 20
Constant speed fuel consumption per 80km/h
<42.5
(L/100 km)
Parking slope (%) 18
Min. turning diameter (m) 15
Approach angle (°) 20 20
Departure angle (°) 13 22, 30
Min. ground clearance (mm) 240
Vehicle start pressure (kPa) 540 ± 30
DFL1120B2 DFL5120XXYB1
Performance parameters
Chassis Chassis
<42.5
(L/100 km)
Departure angle (°) 18 9
DFL1120B complete DFL1120B1 complete

vehicle vehicle
<42.5
(L/100 km)
Departure angle (°) 11 13, 15
DFL1120B2 DFL5120XXYBXX1
complete vehicle complete vehicle
<42.5
(L/100 km)
Departure angle (°) 13 8
CAUTION:
1. Kerb mass of vehicle includes lubricating oil, coolant, fuel, spare wheel and driver's tools.
2. Total weight of vehicle under full load includes the mass of 3 persons in the cab (195 kg).
3. The minimum turning diameter of vehicle is measured from the center of front external wheel
track.
4. The front wheel tread is measured from the front wheel ground contact centers and the rear
wheel tread is measured from the twin tyres centers.
5. The minimum ground clearance refers to the ground clearance of rear axle under full load.
6. The total height is measured, under idle load, from the compartment front bumper for
complete vehicle and from the highest point of cab roof for chassis.
7. The max. gradeability refers to the slope capability of single vehicle under full load.
8. The fuel consumption shown in the table are test data concluded from tests according to the
declared total mass in relevant test standard in National Automobile Quality Supervision and
Inspection Center. The tests are carried out under extremely severe condition which is not
equivalent to the actual operating environment, therefore, the fuel consumption is for
reference only.
Assembly Structure
Assembly Structure
Engine
Manufacturer Dongfeng Cummins Engine Co., Ltd
Type Water-cooled, in-line, 6-cylinder, supercharged & inter-cooled diesel engine
Types of fuel injection Mechanical pump + EGR
Model B170 33 B190 33
Rated power/speed
125/2,500 140/2,500
(kW/r/min)
Max. rated power/speed
121/2,500 136/2,500
(kW/r/min)
Max. torque/speed
550/1,500 670/ (1,300 - 1,500)
(N·m/r/min)
Cylinder bore × stroke
102 × 120
(mm×mm)
Displacement (L) 5.9
Compression ratio (17.3 ± 0.5): 1
Ignition sequence 1-5-3-6-2-4
Fuel (conforming to China III standard): Summer: 0# light diesel fuel; winter: acceptable automobile
diesel fuel according to ambient temperature.
Clutch
Ø395 mm single-plate push-type diaphragm spring clutch, hydraulic control with air booster.
Transmission
Dongfeng/Datong 6-speed transmission operated by remote flexible shaft.
Propeller Shaft
Open-type, cardan universal joint propeller shaft.
Assembly Structure
Front axle
Forged steel part, elliot type I shape beam, steering axle
Front wheel camber 1°

Front wheel alignment
Kingpin inclination angle 7°
angle
Kingpin caster 3°
Max. turning angle of Internal wheel 43°
front wheel External wheel 33°
Driving axle
Dongfeng 416 axle with stamped and welded axle housing; single reduction drive axle. The final drive
ratio is 5.286, and 5.571/4.56 are for option. The rated load on rear axle is 9T.
Wheel and Tyre
Every vehicle is equipped with 7 tyres, including 1 spare tyre.
Rim: 7.0-20;
Tyre model: 9.00-20, 9.00R20 ;
Vehicle frame
Stamped and riveted structure. Max. section size of side rail: 250 mm × 80 mm × 7 + 4 mm. The
reinforcement plate is installed to the middle section of side rail. The outer width of vehicle frame is 860
mm.
Suspension
Front suspension: single front axle, leaf spring suspension. The front spring consists of 7/8 leaves.
Rear suspension: single rear axle, leaf spring suspension. The rear spring consists of 9+6/10+8 leaves.
Steering System
Power steering system, integral power steering gear, vane steering hydraulic pump.
Assembly Structure
Brake System
a) Main equipment of brake system:
Air compressor: single-cylinder water-cooled air compressor, optional dual-cylinder air compressor for
some models.
Air reservoir: four 30 L air reservoirs;
Valves: foot brake valve, manual valve, manual valve of trailer brake, air processing unit (APU),
differential valve, quick release vale, exhaust brake valve, pipe joint assembly (including check valve),
load sensing valve, trailer valve and ABS solenoid valve.
b) Service brake: dual-circuit suspended brake valve and drum brake (or front-disc rear-drum wheel
brake).
c) Parking brake: manual valve controlled spring brake chamber, acting on the driving wheel(s).
d) Auxiliary brake: butterfly valve electric-pneumatic operated engine exhaust brake.
Electrical System
The 24 V circuit system is applied. The system is negative grounded.
Main electric equipment and instrument parameters:
Battery 12 V 100 A·h or 12 V 140 A·h (2 pcs)

Alternator 28 V, 70 A
Starter 24 V, 6.0 kW
Instruments: Speedometer, tachometer, water temperature gauge, fuel gauge and barometers.
Lamps: front combination lamp, rear combination lamp, side turn signal lamp, rear working lamp, front
fog lamp, end-outline marker lamp, marker lamp, cab interior lamp etc.
Indicator and alarm: refer to the specific configurations of cab.
Switches: refer to the specific configurations of cab.
Assembly Structure
Cab
The flat roof cab is of tiltable cab-over-engine type, adopting hydraulic tilting mechanism. It has a
two-stage boarding step. In the front row inside the cab are the driver's seat, middle seat (or centre glove
box) and passenger's seat. The driver's seat is airbag shock-absorbing seat, backrest angle of which
allows front and back adjustment. The passenger's seat also allows front and back adjustment of
backrest angle. The rear row is provided with a berth of 2,025 mm × 550 mm. The cab is also equipped
with heat insulation carpet, glove box, cigar lighter, radio & MP3 player, interior rear-view mirror, sun
visor and curtain rail. Both doors are equipped with central door lock, and the door glass can be lifted
while the rear window cannot open. It is equipped with tiltable face shield and metal bumper. The front
windshield is equipped with electric wiper and washer, exterior rear-view mirrors are mounted on cab left
and right side, lower vision mirror and wide-angle lens are installed at passenger’s side and the latter is
optional for driver’s side.
Heater and A/C
The cab is equipped with heater, and A/C (optional).
The cab refrigeration system employs environment-friendly fluoride-free A/C system and uses R134a as
refrigerant.
Carriage
The truck carriage applies iron-wood composite structure.
Driver’s Tool
Each commercial vehicle is equipped with one set of driver's tools.
Schematic Diagram of Brake
Schematic Diagram of Brake

The electrical schematic diagram attached in this manual is a general electrical schematic diagram.
Refer to the specific configuration when using it.
1. Air compressor 8. Spring air chamber with 12 valves

2. Air processing unit 9. Manual valve
3. Brake valve 10. Front air reservoir
4. Quick release valve 11. Rear air reservoir
5. Front air chamber 12. Auxiliary air reservoir
6. Load sensing valve 13. Joint assembly
7. Spring air chamber with 11 valves 14. Differential valve
Diagnostic Fault Code List of Speed Governor (Optional)
Diagnostic Fault Code List of Speed Governor (Optional)

Flash code Fault code
11 Fault lamp short circuited to ground
22 Speed signal short circuited to ground
24 Speed signal fault & circuit break
31 Actuator potentiometer faulted
33 Internal electronic failure
34 Road speed pulse error
35 Configuration data error
41 Internal circuit & actuator short circuited
42 Actuator wiring short circuited to ground
43 Actuator motor overloaded
44 Actuator motor open circuited
45 Actuator lever arm blocked
Electrical Schematic Diagram

The electrical schematic diagram attached in this manual is a general electrical schematic diagram.
Refer to the specific configuration when using it.
Electrical Schematic Diagram (Applicable for T2R30 Complete Vehicle) 4-1
C17 56 13 2 c28 28 c16 60 50 21 1 C5 C2 29 72
Starting system Preheating system Brake Reversing Working lamp Radio & MP3 player Cigar lighter Horn Air dryer Dome lamp Reading lamp
0290 5.0 0290 0290 0290

0260 5.0 0260 0260 0260
0250 8.0 0250 0250 0250
0209 2.0 0209
29
56 15A
120A 10A 10A 15A 5A 10A 10A 10A 10A 15A
30A
0201 3. 0
10A
0716 1. 0
0602 1. 0
0291 1. 0
0502 1. 0
0701 1. 5
0720 1. 0
0722 1. 0
0711 1. 0
0007 8.0
0307 5. 0
300- 00 2. 0
0211 1. 0
S R Ig Acc B
OFF
Acc
G ON
ST
21
0202 1.0 0204 0.5
0205 1. 0
30A 5A Reserved electrical
5A 28 connector
10A
Power switch
2 0702 2.5
0291
10A 0500 1.0 72

0292 0. 5
0203 1.0 0208 2.0
Reversing lamp relay

C17
21
22 10A 20A
5 1
Fuel preheating relay

Fuel preheating switch
0
5. 0
Diagnostic socket 1
Master power switch
Air dryer switch

power 1 5
0713 1. 0
0293 0. 5
Brake switch
0309 1. 0
Left step lamp

1
10W
0200
0710 2. 0
0704 1. 0
Neutral switch
Berth reading lamp

0717 1. 0
0712 0. 5
Right front reading lamp

1 5
Left front reading lamp

5 1 7 0
0 1
0501 1. 0
1
B
Horn button
c28 c16
0600
0721 0. 5
0308 5. 0
0723 1. 0
13
0601
For trailer only
0207 1. 0
0061 2. 5
0714 0. 5
0715 1. 0
Radio &
Auxiliary starting button
Fuel glow plug
on
1
on
0212 1. 0
MP3 player
Brake lamp relay
door
C2
1415 0. 5
1408 0. 5
60 E F
Seat belt indicator switch
Reversing switch
0508 1. 0
Cigar lighter
Parking brake switch
Reversing lamp
0507 1. 0
0706 0. 5
0709 0. 5
0708 0. 5
0707 0. 5
15W
Air horn solenoid valve
Fluorescent lamp
1
起动机
Electric horn
0724 0. 5
0505 1.0
Air dryer
3 Spot
0100 5. 0
Working inspection
lamp light
Right brake lamp

Left brake lamp
0310
0. 5
H
0501 1. 0
0290
C5
Right door
lamp switch
Left door lamp switch
2 C1
Buzzer
(4D4)
0208
28
5A 5A 22
Shut-down switch
0409 0. 75
0401 1. 0
For concrete mixer chassis only
0292 0. 5
21 Speed mileage sensor
CC/ PT O Switch
Electronic throttle Water level sensor Remote throt le position sensor 5 1 7 6 2 8
Air pressure signal

0 5 5 2 0 . 5 Clutch switch
for front axle

Remote PTO switch
Exhaust
0
switch
1445 0. 75
brake
1448 0. 75
1
1 2
Air pressure sensor
for rear axle

Air pressure signal
power supply
1. 0
1. 0
1. 0
1. 0
1. 0
1. 0
0291
. 5 0550
50
0445 0. 75
Regulating switch
Set/R
0483 0. 5
0028 0. 5
0504 0. 5
0045 0. 5
1418 0. 5
1420 0. 5
1422 0. 5
1419 0. 5
0047 0. 5
0555 0. 5
0559 0. 5
1485
1404
1405
1403
1484
1486
0. 5
0. 5
0. 5
0. 5
1103 0. 5
0203 0. 5
1 0switch
Switch
5 5throttle
0556
51
1411
1412
1413
1414
0Remote
04 45 27 35 28 26 25 22 60 38 37 19 30 16 05 08 07 15 18 41 24 C13 A18 A15 A33 A11C27 A12 A8 1 2 3 1+ 2 3 4

+ S1 - 5V S2 - R S Instrument - SI/O
Tachograph
EECU For Version D ECU only 01 21 P-A P-B
01 55 32 54 44 13 52 H L A22 A21 A25 A26 A16 A34 A35 A14 A31 A13
5 6 6
c
Air filter clog sensor

Sensor GND
1411 0. 75
Vehicle speed sensor power supply
Vehicle speed sensor signal
1413 0. 75
1412 0. 75
56
1417 0. 75
02-60
1409 0. 5
Exhaust brake solenoid valve
0554 0. 75
0301 0. 75
0303 0. 75
0553 0. 75
CAN bus
0100 4. 0
(ECM 22) (ECM 26) 0015 0.5

0557 0. 5
Master power
switch
C4
1. 0
1. 0
0014 0.5
10A
1447 0. 75
Electric fan solenoid valve
Fuel level sensor

c
Preheater relay
Diagnostic interface
Electric fan speed sensor
20 The signal of the speed mileage sensor shall be sent to the tachographs, if installed.
C7 20 The signal of the speed mileage sensor shall be sent to the instrument if the
(Exhaust brake valve) tachographs is not installed.
Instrument 2
28 22 20 56 20 21 D530.KD1.H111103
1 C9 C14 C10 C3 C22 A29
72
Tractor lamp Wiper Manual A/C & heater system High/low beam Clearance lamp Fog lamp Turn signal lamp
0260
0250
15A 15A 15A 20A

15A 10A 10A 10A 10A 15A
0900 1. 5
0800 1. 5
0740 1. 5
0730 1. 5
1200 1. 0
1206 1. 0
1101 1. 0
1301 1. 0
1005 1. 5
1001 1. 5
High beam relay
Low beam relay

0702
72
0905
0801 1. 5
1302 1. 0
1006
1102
1002
1309 1.0
Turn signal switch
Hazard warning switch

1 2 3 4 5 1009 0.5
0731 1. 0
OFF 1 2 3 4 5 6 7 8
Fog lamp switch

AC switch
Rear fog lamp switch

Wiper
Water 1 Air circulation
1007
1003
injector 2
0903
0904
device
1 5
1103 1. 0
3
1205 0. 5
4
0802
0803
0808
0806
1201 1. 0
Thermostat
1207 0. 5
1206
DC-DC
1200
7 8 9 1 10
Tractor working lamp
Wiper intermittent relay C D
Pressure switch Compressor
1305 1. 0
1306 1. 0
2 3 4 5 6
1104 0. 5
1105 0. 5
M 1202 0.5
0811
0810
0814
0812
0813
0. 75
0. 75
C3 G
16 17 18 19 20 26 P
0. 75
0. 75
Right front turn signal lamp

1. 0
1. 0
Left rear turn signal lamp

K J
0. 5
Right side turn signal lamp

Left front turn signal lamp
0909
Right rear turn signal lamp

OFF
Left turn signal lamp

Right inner headlamp
Left inner headlamp
1204 1. 0
Wiper
1203 1. 0
Left rear clearance lamp
INT
C10 C22 A29
Right rear fog lamp

Right rear clearance
Left front fog lamp
Right front fog lamp

LO
Left rear fog lamp

Clearance lamp
Clearance lamp
HI C9
lamp
Washer WASH C14
0100
0260 0260 0260

0250 0250 0250
0702 0702 0702
0208 0208 0208
15A
Clearance lamp switch
Brake lamp switch
5A 5A
1. 0
6. 0
1. 5
15A
Rear fog lamp
switch
ABS diagnostic switch

5A 25A 5A 1309
1700 0. 75
To exhaust brake switch

1 5
Turn signal switch
warning switch
0 For Version D only
1703 2. 0
Filament detector
For Version D only
13 1
1781 1. 5
G
1780 6. 0
C12
1301
2. 5
Hazard
50
0212 0. 75
0. 5
1. 0
1
0. 5
1701 2. 5
B 21 Left front sensor Right front sensor Left rear sensor Right rear sensor
1304
1307
1302
DBR relay
0550
A6
1103
0705
Trailer ABS warning lamp

1202
1416
G M G M G M G M A4
1704 0. 5
1 4 11 12 10 7 22 1 2 3 4 5
1783 0. 5
05510. 5
1741
1742
1745
1746
1731
1732
1735
1736
1602 0. 75
Flash unit
1707
Integrated alarm 51
2 3 5 6 9 8 20 13 0014 15 1 14 7 8 15 15 12 13 10 14 11 18 17 10 17 11 14 16
11
Right brake lamp
Right rear clearance lamp
Left brake lamp
Right rear fog lamp
Left rear fog lamp

Left rear clearance lamp
0015 0014 3 14pin 18pin
1305
1306
1311
1312
12 K L K L
2 8 10 1 10 11 13 4 9 6 3 4 1 5 2 9 8
Trailer right turn signal lamp

Trailer ABS socket
Left front turn signal lamp
Right front turn signal lamp
Right side turn signal lamp

Left side turn signal lamp
Trailer left turn signal lamp

Tractor left turn signal indicator
Trailer left turn signal lamp Indicator lamp
Trailer right turn light indicator

Tractor right turn signal indicator lamp
0015
Left rear turn signal lamp
Right rear turn signal lamp

1603
For Version E only

C D E F J K H
1751
1752
1755
1756
1761
1762
1765
1766
1711
1710
0051
0054
0051 0. 75
0054 0. 75
Door switch
A13 A8
1. 0
1601 2. 5
A E A E A E A E
1418
1417
A27 A19
1541
1542
Air filter clog (sensor)
O O O O
Fuel level sensor
A9 Left front valve Right front valve Left rear valve Right rear valve
M
1791
1792
1795
1796
10 11
1 5
High-gear switch
High-gear switch
0
2. 5
1
ABS flashing code switch 17-06 ABS 4S4M For tractor
0100 A31 For Version E only 0100
1 A31 16 72 C12 H 13 22 10 11 50 51 A9 A6 A4
A13 A8 A27 A19
Sensor Cab tilting 4-channel ABS Trailer ABS

D530.KD1.H111103
1 19 10 11 A32 C24 C6 60 C25 18
Electric rearview mirror Rearview mirror defroster ECAS Air suspension
0260 0260 0260

0250 0250 0250
0703 0703 0703
0208 0208 0208
10A 15A 5A 5A 5A
15A
1700 1.0
2100 1.0
2101 1.0
2000
1900 1.0
1910
18
Electric rearview mirror switch
1500
7 6 5 4 3 2 1
Direction adjustment
OFF
R 2 1
Air suspension
control switch
L 0043
U Remote 3 20 9 1 15 2107 0.75 1 3 5 7
D control 4 0044 Rear suspension
21 solenoid valve
OFF
19 ECAS I
L 2003 13 2108 0.75
Rearview mirror defroster switch

mirror selector
II
Left/right
N 841 801 779 0
Defroster relay
R K
0051 0.75 4 ECU
10 25 2105 0.75
1905 1.0
1904 1.0
1.0
1901 1.0
1903 1.0
0054 0.75 2
L 22 34 33 16 27
2191 1.5
2190 1.5
1902
0.75
0.75
Electric rearview mirror lever switch
0.75
2002
2 4 5 3 1 6 7 11
M M
Left rod
ON Height
Diagnostic
0505
2102
2103
1409
sensor
M M OFF
socket
Rearview mirror heating resistor

4410500110
1911
1912
A32 C24 C6 60
mirror (LH)
Side view
Side view
mirror (RH)
Vehicle
Alarm Failure Brake
speed
M pulse
1
signal
C25
0100 0100
0290 0290
0702 0702
0250
15A 19 10A 10A

15A 2300 1.0 ON OFF
1 7 5
1500 1.0
2403
2400
2404
2402
2201 1.5
Door lock 2 1 11 12 13
Electric sunroof controller
time switch 5 6 10 7 8 9 18
Bogie differential Inter-wheel
PTO switch Lifting switch switch differential switch
2207
2206
2202
2203
1 5 1 3 7 1 5 1 5
2408
2409
Lifter
2301
2407
2302
2405
2406
PTO
OFF UP OFF OFF
M M ON OFF ON ON
1511 0.5
1501 0.5
2205 Left door window
DOWN
Right door window regulator motor M

2209
regulator motor Sensor
1510 0.75
2204 2208
1530 0.75
1520 0.75
Central lock
5 4 3 2 1
1511 0.75
1501 0.75
actuator
Multi-functional buzzer
C20 C23
C15 C11 12 1110 9 8
Differential
Reserved
1521 1.0
1531 1.0
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
UP UP UP
1520 0.5
O O O
DOWN DOWN DOWN
A7
Bogie differential sensor

Lifting buzzer
A10
PTO solenoid valve
sensor
differential
Inter-wheel
0100 0100 0100
Electric regulating door and window Central door lock Electric sunroof PTO/lifter/differential
19 A7 A10 C20 18 C23 D530.KD1.H111103
C15 C11
when open circuited)
(Collector output
D530.KD1.H111103
A2
Vehicle speed signal

output GND
C19
Vehicle speed signal output

A32
(11V)
Vehicle speed
signal output 1
A31
1412 0.5
Sensor GND
Speedometer
1413 0.5
C13
A14
Normally Vehicle speed

powered on+ sensor signal
4-4
1411 0.5
A35
Vehicle speed sensor

A34
power supply
Instrument
power supply-
Fuel gauge
1422 0.5
A12
A33
Instrument
Air pressure signal
power supply+ for rear axle
1420 0.5
C27
Air pressure sensor

power supply
A16
1419 0.5
Instrument
A11
Barometer
Rear axle
power supply-
(Lower)
Air pressure signal

A18
for front axle

0401 1.0 1417 0.5
A15
A13
Instrument
Electrical Schematic Diagram (Applicable for T2R30 Complete Vehicle)
Fuel level sensor

power supply+
Barometer
Front axle
(Upper)
C8
Transmission
buzzer
A10
A7
PTO indicator
Low air pressure alarm
Exhaust brake indicator
Instrument principle
C7
C4
Alarm buzzer Inter-wheel differential
indicator
C11
Bogie differential indicator
C15
Tachometer Floating axle alarm
Ajar alarm
A36
Tractor left turn
C5
CAN bus
Water
thermometer Brake shoe indicator signal lamp
C22
A1
Trailer left turn
Charging indicator
signal lamp
C21
Tractor right turn
C17
High water temperature alarm ASR indicator lamp signal lamp
A29
A9
can_h
Trailer right turn

A21
0014
ECAS warning lamp signal lamp
A30
C24
Low water level alarm
ECAS failure lamp
High beam
C6
C9
can_1_1
Filament detector
A22
Low beam
Shut-down alarm
C12
C14
Tractor ABS indicator
0020
Maintenance alarm Front fog lamp

CAN bus
A6
C10
Parking brake:
can_1_2
A5
Low oil pressure alarm Rear fog lamp
C16
0015
Air filter clog indicator
C3
A8
Water-in-oil indicator lamp Air dryer indicator
Seat belt indicator
C2
C28
Service indicator lamp High gear indicator Air suspension
can_m indicator lamp
A23
A27
C25
Low gear indicator
Wait-to-start indicator lamp
Fuel preheater
A19
ABS Trailer indicator
C1
Cruise indicator
Engine power output
can_shield
Retarder indicator
A4
A24
Transmission failure
A28
electronic control system
A3
Instrument lighting
Subtotal/total mileage
LCD segment display:
Fault code of engine
C26
A18(+)
A17(-)

DFL1120B

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DONGFENG MOTOR CO., LTD.

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Location of Engine Nameplate and

1. Location of engine nameplate

Running-in of New Vehicle

For the vehicle equipped with electromagnetic master power switch:

Initial state State before welding

Specific operation steps:

Precautions for Load Sensing Valve

Please refer to the specific configurations of your

Structure and Operation

1. Air vent at driver’s side (see Page 40) 9. Brake pedal

1. Locking position 3. Key inserting

From the inside

Please refer to the specific configurations of your

Passenger’s seat (mounting frame)

1. Pulling the seatback tilt adjusting lever can

1. Seatback tilt 2. Head restraint

Passenger's seat (mechanical shock absorbing type with slide rail)

1. Pulling the seatback tilt adjusting lever can

Middle seat Direction for

Driver’s and passenger’s seat belts

1. Buckle 2. Latch plate

Middle seat belt

1. When using the berth for a rest, please make

1. Water thermometer 8. Center/Rear axle barometer

The water thermometer indicates the temperature

Turn light indicator

Speedometer indicates the running speed of the

The barometer indicates the air pressure in the air

1. Front axle barometer

Overspeed alarm indicator lamp (optional)

Indicator lamp and alarm lamp

Low beam indicator lamp

This indicator lamp will be on when the

Parking brake indicator lamp

Filament detection alarm lamp

Charging indicator lamp

Low oil pressure alarm lamp

This lamp will be on when the key is turned to ON

High beam indicator lamp

Exhaust brake indicator lamp

Rear fog lamp indicator lamp

Air dryer heater indicator

This indicator lamp will be on when the air dryer

Seat belt indicator lamp

Door ajar alarm lamp

Front fog lamp indicator lamp

Air filter clog alarm lamp

When this lamp is on, it means large intake

Tractor ABS malfunction indicator lamp

Low water level indicator lamp

Please refer to the specific configurations of your

Instrument buzzer warning

Mileage Display Screen

Backlight adjusting knob

Master power switch

Front fog lamp switch

Rear fog lamp switch

Hazard alarm lamp switch

Air and electric horn transfer switch

During driving, operate this switch to switch