Preface

Welcome you to become one member of DONGFENG light-duty commercial vehicle users.
We aim to give the best benefit to the your purchased DONGFENG light-duty commercial vehicle, therefore we hope
you could read this manual completely before using this vehicle so as to learn the operation.
This manual is suitable for Dongfeng Captain series vehicle.
This manual, not for sale and attached to the vehicle, should share the same model with the purchased vehicle. In case
of any mistake, please contact with the dealers and then store them on the vehicle. The figures in the manual are correct
during publishment, but may be different from the actual structure as the product structure continuously improves. For
more information, please contact with our company. The transfer of this vehicle should be together with the new
owners.
With no written permission from our company, do not print, translate or abstract this manual. Our company reserves all
copyrights and rights of modification. Any change of equipment and technologies will be carried out without prior
notification.
Contact with agent of overseas business department of Dongfeng for product sales, quality warranty and spare parts
purchase.
Units used in this manual are legal.

DONGFENG AUTOMOBILE CO., LTD.

March 2021
 Dongfeng Light-duty Vehicle
FULL OF HOPE AND ACHIEVEMENT

Maker/Dealer
DONGFENG Automobile Co., Ltd

All Rights Reversed

Before reading
This manual, as the part of this vehicle, should be stored on board.
Contents
The Contents list the main outlines of this manual.
Directions
The directions (front, rear, left and right) are conditioned by the vehicle forward traveling.
Pictures
Pictures in this manual are only for easily understanding this manual content and operation manual, and therefore may
be different from the real projects. In such case, the real product prevails.
Warning
Caution:
Any nonobservance of the stipulations could possibly lead to the personal injuries, parts assembly and whole vehicle.
For example:
Caution: After the door is closed, recheck it, as it is very danger when the vehicle runs with the doors semi-closed.
Danger
Any nonobservance of the stipulations could possibly lead to the personal injuries, or severe property loss. For
example:
Danger: Do not adjust the seat during vehicle running.
Notice
Attention: It’s prohibited to modify or add any product safety related equipment
without prior consent.
Warning: in case of refitting or installation of additional electric equipment, use
authorized products of Dongfeng.
Warning: Before welding the vehicle, disconnect the cable from the battery.
 Contents
Preface............................................................................ 4
Before reading ............................................................... 1
Notice.............................................................................. 6
Contents ......................................................................... 1
Vehicle identification.................................................. 1-1
Location of vehicle nameplate ............................. 1-1
Position of engine nameplate ............................... 1-1
VIN position......................................................... 1-2
Daily inspection .......................................................... 2-1
Before inspection ................................................. 2-1
Step 1 ................................................................... 2-1
Inspection in cab .................................................. 2-1
Check the chassis ................................................. 2-2
Check the engine after startup .............................. 2-5
Inspection of vehicle pilot run ............................. 2-6
Inspection after trial run ...................................... 2-7
Others .................................................................. 2-7
Structure description and operation(old cab) ......... 3-1
Layout of control area (status 1).......................... 3-1
Layout of control area (status 2).......................... 3-2
Layout of control area (status 3).......................... 3-3
Layout of control area (status 4) .......................... 3-4
Layout of control area (status 5) .......................... 3-5
Layout of control area (status 6) .......................... 3-6
Layout of control area (status 7) .......................... 3-7
Layout of control area (status 8) .......................... 3-8
Door..................................................................... 3-9
Seatbelts ............................................................ 3-10
Instrument cluster (status 1) .............................. 3-12
Instrument cluster (status 2) .............................. 3-13
Contents
Instrument cluster (status 3) ............................... 3-14
Instrument cluster (status 4) ............................... 3-15
Instrument cluster (status 5) ............................... 3-16
Adjustment of seat ............................................. 3-27
Vehicle keys ....................................................... 3-28
Ignition lock ....................................................... 3-29
Combined switch (lighting part) ........................ 3-30
Combined switch (wiper and washer) ................ 3-32
Headlamp dimmer switch .................................. 3-35
Radio/MP3 player .............................................. 3-35
Cab ceiling lamp ................................................ 3-36
Cab sunroof ........................................................ 3-36
A/C system (status 1) ......................................... 3-37
A/C system (status 2) ......................................... 3-38
Levers, steering wheel and accessories .............. 3-41
Rear side window............................................... 3-53
Installation / removal of power supply wire ...... 3-53
Operation of spare tyre unit ............................... 3-54
Cargo box fence levers ...................................... 3-54
Cab tilting .......................................................... 3-55
Filler cap ............................................................ 3-56
Fuse box ............................................................ 3-57
Structures descriptions and operations (B19 cab) .. 4-1
Arrangement of driver zone................................. 4-1
Combination instrument ...................................... 4-2
Vehicle key ........................................................ 4-10
Ignition switch ................................................... 4-10
Combination switch ............................................4-11
Fog lamp switch ................................................ 4-13
Multi-functional steering wheel ........................ 4-14
Cruise control - status I ..................................... 4-15
Cruise control - status II .................................... 4-16
PTO function - status I ...................................... 4-16
PTO function - status II ..................................... 4-17

Headlamp dimmer switch .................................. 4-18
Daytime driving light ......................................... 4-18
Re-generation switch (if equipped) .................... 4-18
OBD port............................................................ 4-20
Central control panel .......................................... 4-21
A/C system ......................................................... 4-22
Radio .................................................................. 4-23
Intelligent on-board terminals ............................ 4-26
Cigarette lighter ................................................. 4-27
Ashtray ............................................................... 4-27
Roof lamp .......................................................... 4-28
Lever, steering wheel and accessories................ 4-28
Rearview mirror ................................................. 4-29
Rear side window............................................... 4-29
Electric window ................................................. 4-30
Micro-wave window .......................................... 4-30
Contents
Door................................................................... 4-30
Seat adjustment ................................................. 4-31
Seatbelt .............................................................. 4-32
Removal of power wire ..................................... 4-33
Operations on spare tire ..................................... 4-33
Operation of rear fence ...................................... 4-33
Cab tilting (L-shape cab) ................................... 4-34
Cab tilting (S-shape cab) ................................... 4-34
Fuel tank ............................................................ 4-35
Fuse case ........................................................... 4-37
Driving vehicle ........................................................... 5-1
Startup of engine ................................................. 5-1
Start of engine with cab tilted .............................. 5-2
Startup by the assist battery ................................. 5-3
Driving precautions ............................................. 5-3
Brake operation ................................................... 5-4
Contents
Parking brake ....................................................... 5-5
Traveling on the slope .......................................... 5-5
Anti-lock brake system (ABS) (Optional) ........... 5-6
Clutch operation ................................................... 5-7
Precautions after engine shutdown....................... 5-7
Maintenance of vehicle .............................................. 6-1
New vehicle running-in and maintenance ............ 6-1
Air cleaner............................................................ 6-2
Draining coolant out of cooling system ............... 6-3
Inspection of thermostat starting temperature ...... 6-3
Water-draining port on the water pump ............... 6-4
Venting the fuel system ........................................ 6-4
Exhaust turbocharger ........................................... 6-4
Air dryer (If equipped) ......................................... 6-5
Oil filter................................................................ 6-6
Fuel prefilter......................................................... 6-6
Fuel filter and fuel-water separator ...................... 6-6
Drain the water out of fuel tank........................... 6-7
Use and maintenance of SCR system .................. 6-7
AdBlue reservoir (if equipped) ............................ 6-8
Maintenance and repairing of metering injection
pump .................................................................... 6-8
Compressed air filter ........................................... 6-9
Maintenance and servicing of temperature sensor
and nitrogen oxygen sensor ................................. 6-9
Maintenance and servicing of nozzle .................. 6-9
Manual engine water valve.................................... 6-9
Engine lubricant ................................................ 6-10
Inspection and filling of oil level in clutch oil
reservoir ..............................................................6-11
Inspection, refilling and change of lubricant in the
gearbox .............................................................. 6-12
Inspection, refilling and change of lubricant in the
final drive of rear axle ....................................... 6-12
Inspection, filling and replacement of power
steering gear oil ................................................. 6-13

Maintenance of wheel hub bearing .................... 6-14
Brake pedal travel .............................................. 6-14
Draining water out of the air reservoir ............... 6-15
Operation and maintenance of battery ............... 6-15
Fuse .................................................................... 6-17
Inspection of wiring harness .............................. 6-17
Suspension ......................................................... 6-17
Wheel rotation.................................................... 6-18
Tyre replacement ................................................ 6-18
Inspection of tire pressure and tread .................. 6-19
Clean and replacement of wiper blade ............... 6-20
EURO-VI aftertreatment system ........................ 6-21
Adjustment of vehicle ................................................ 7-1
Precautions of parts of engine environmental
compliance. .......................................................... 7-1
Provisions to be followed during maintenance .... 7-1
Tension of fan belt................................................ 7-2
Contents
Clutch adjustment (with clutch booster).............. 7-2
Draining of clutch (with vacuum booster) ........... 7-3
Adjustment of parking brake travel (Central drum
type) optional....................................................... 7-3
Manual adjustment of service brake (air brake) (if
equipped) ............................................................. 7-4
Manual adjustment of service brake (hydraulic
brake) (if equipped) ............................................. 7-5
Auto adjustment of service brake (if equipped) .. 7-5
Air bleeding of hydraulic brake system............... 7-5
Adjustment of wheel hub bearing........................ 7-6
Adjustment of the free travel of steering wheel .. 7-7
Front wheel toe-in adjustment ............................. 7-8
Maintenance period and data ................................... 8-1
Regular service table ........................................... 8-1
Parts to be periodically replaced........................ 8-37
Main adjustment data ........................................ 8-37
Contents
Fuel .................................................................... 8-38
Parts to be greased and intervals ........................ 8-40
Lubricant and oil ................................................ 8-42
Engine lubricant ................................................. 8-43
Engine lubricant (for pressure common-rail fuel
injection electronic-control engines) .................. 8-44
Gear oil of drive axle ......................................... 8-45
Power steering oil .............................................. 8-46
Grease ................................................................ 8-46
Clutch booster fluid............................................ 8-47
Engine antifreeze ............................................... 8-47
Tightening torque....................................................... 9-1
Engine .................................................................. 9-1
Cab and chassis .................................................... 9-2
Appendix 1: On-board Provision List ......................... 1
 Vehicle identification

Vehicle identification
Position of engine
Location of vehicle nameplate
nameplate

(status 1) (status 2)

1-1
Vehicle identification

VIN position

VIN is stamped at the mid or rear

portion of frame, and the practical
objects prevail.

1-2

Daily inspection
Driver should carefully check the
vehicle each day, on which the
traveling safety is directly dependent.
In order to prevent against the
accidents to ensure the traveling
safety, Driver should carefully check
the vehicle each day.
Before inspection
Park the vehicle on the flat ground,
turn the ignition key to “OFF”, and
ensure the parking brake could work
normally and then shift the gear lever
to the neutral.
Step 1
Check the abnormal parts found at
the previous day;
If the abnormal parts have already
been repaired at the previous day,
confirm it again.
Inspection in cab
Check the driver’s seat
Adjust the driver's seat to the best
position suitable for driver stature to
ensure the travel safety. For the
methods to adjust the driver’s seat,
refer to “Structural Illustration and
Operation”.
Danger: do not adjust the driver'
seat during traveling.
Check the seat belt
Before inspection, wear the seat belt.
After that, forcefully tension the seat
Daily inspection
belt to ensure the lock elements are
reliably connected.
Check if the seatbelt belt, buckle and
retractor are intact.
Caution: the seat belt is valid for
one accident only. In case of an
accident or if the belt has been
damaged, please repair.
Danger: for your safety or others,
with the seat belt failed, do not drive
the vehicles.
Check all kinds of mirrors
The glasses (including the rearview
mirror) surrounding the cab should
be clean to ensure the view field is
clean.
Danger: during traveling, do not
adjust all kinds of rearview mirror.
Check the door for lock.
Check the door locking condition at
the driver’s side as well as the
2-1
Daily inspection
co-driver’s side. Inspect if the glass
elevators at both sides work well.
Check the windshield washer
fluid level.
Check the windshield washer fluid
level, if needed, refill it.
2-2
Check the fuel level Check coolant level(status 1)
Speed indication
Oil level Water temperature
indication
indication
1/2 mark position
Alarm zone 1/8
Urea tank liquid level
indication
Total mileage
Turn the ignition switch to “ON” to
check the fuel level, and refer to the Before adding the coolant, check the
travel mileage on that day to refill it. engine and radiator for presence of
leakage and repair any leakage
Check the chassis detected. Add coolant through the
filler port of expansion tank, till the
Before inspection, tilt the cab.
level is between upper and lower
limits.
Check the sealing and working status
of the filler port pressure cap.
Caution: It’s prohibited to use
running water or hard water from
well or river instead. The failure to

use anti-rust antifreeze coolant will
lead to formation of water scale in
cooling system and overheating of
engine.
Check coolant level(status 2)
1. Coolant reservoir 2. Hood
Coolant is at the front-right side of
cab. To check the coolant level, just
open and rotate the hood.
Manual opening of hood
1. Slightly pull the unlocking
panel at the driver’ side, half
opening the hood.
Daily inspection
2. Move the lock handle at the overheating the engine.
inner-middle-upper side of hood
towards the right, and gently
Check crankcase ventilation
rotate it to fully open the hood. pipe
Check the engine and the radiator
don’t leak before the coolant filling
and repair it if needed. Besides, the
coolant should be added from the
filler port until between the upper
and lower limits.
Check if the pressure cap of filler is
sealed up and works normally.
Hood closing During the operations in cold
Forcefully and slowly press the hood weathers, check the crankcase
to lock it. ventilation pipe daily for the
Caution: It is recommended to use blockage of ventilation pipe due to
the long-lasting anti-rust and freezing.
anti-freeze coolant from Dongfeng Upon detection of freezing,
and prohibited to add any tap disassemble the ventilation pipe and
water, well or river. If the when necessary remove the blockage
anti-freeze and anti-rust coolant is material from the pipe.
not used, there will be scale
generated in the cooling system,
2-3
Daily inspection
Fuel-water separator
Daily drain water and deposits from
fuel-water separator.
Caution: Drain the water from the
fuel-water separator into a container
and dispose as per the environmental
regulations.
2-4
Check the engine lubricant
level
Up
Down
Generally, the engine lubricant level
should be located at the upper scale
and lower scale of oil dipstick.
Replenish the oil if needed; if the oil
level exceeds the upper scale, drain
the surplus oil to the proper level.
Danger: if the engine lubricant level
is lower than the desired value, the
engine will be burned.
Check the brake pipeline
Check the brake pipeline for oil/air
leakage.
Check the steering system
Cold
Hot
1. Steering oil reservoir
2. Steering oil reservoir and dipstick
Check all kinds of bolts and nuts for
tightness.
Check the power steering system (If
equipped) for leakage, if so, repair it
firstly.
Check the power steering fluid, refill
it if needed.
Check the suspension
Check the front and rear leaf spring
for damage, as well as the bolts and

nuts for tightness.
For the tightening torque of bolts and
nuts attached to the suspension
system, refer to the “Tightening
Torque”.
Check the tire pressure and its
state
Check the tires for damage or scratch.
Periodically check the tires for
irregular wear.
Check the engine, gearbox and
drive axle for leakage.
Check the harness
Check whether the harness rubs with
other parts, or there is grounding or
damage phenomenon.
Check the engine after
startup
Check each instrument for
normal work
 The engine lubricant pressure
indicator should show the normal
pressure range. If the engine oil
alarm indicator does not go out
within 15s, please immediately
shut down engine for repair or
inspection.
 The coolant temperature gauge
should read normally.
 Check whether the tachometer
could work normally.
 Whether the battery charge
indicator goes out or not.
Check the horn
Press down the horn to check
whether the horn could sound
Daily inspection
normally.
Check the lighting
Lighting switch
1st position
2nd position
Rotate or upward/ downward/
forward/ backward move the
combined switch to check whether
the each lighting or signaling lamp
could work normally.
Check the windshield wiper
and washer
Before inspection, firstly clean the
windshield. Then spray the washer
fluid to observe whether the washing
agent is normally sprayed. Ensure
2-5
Daily inspection
the wiper could work normally at
each gear.
Check the steering wheel free
travel and loose status.
Free travel
With the front wheels at straight-line
state, slight turn the steering wheel
leftward and rightward to check the
free travel.
Lateral and radically rock
steering wheel to check
looseness.
2-6
Inspection of engine exhaust Inspection of vehicle pilot
system run
Brake inspection
Stop
After sufficiently preheat the engine,
check the exhaust color:
 Colorless or light blue: normal; Check the brake pedal to ensure the
braking reaction period and
 Black: abnormal, incomplete
combustion efficiency are normal.
 White: oil is burning, however,
the when the ambient temperature or
for engine temperature is low, the
smoke it also white.
At the same time, monitor whether
the engine is normally sounding or
vibrating.
 Daily inspection
Inspection of steering system After trail run, check the vehicle for
air/gas/coolant leakage.
Others
Above are inspection tasks before
driving. In case of any abnormal
phenomenon during the inspection,
Joggle please adjustment or repairing.

During trial run, check the steering

wheel for normal vibration, with no
rocking, high resistance or offset.
Inspection after trial run

2-7
 Structure description and operation(old cab)

Structure description and operation(old cab)

Layout of control area (status 1)

1. Adjust switch of headlamp beam 8. A/C-heater switch 15. Glove compartment

2. Vent 9. Fan switch 16. Combination switch (lighting module )
3. Hazard warning switch 10. A/C and heater switch 17. Combination switch(Wiper and Washer)
4. Storage box 11. A/C switch 18. Ignition lock
5. Ashtray 12. Air internal/external circulation switch 19. Front right power glass and PTO adjust switch:
6. Cigarette lighter 13. Combine instrument 20. Console piano-key switch
7. Radio-MP3 player 14. Glove compartment

3-1
Structure description and operation(old cab)
Layout of control area (status 2)

1. Plug 8. A/C and heater change-over switch 15. Combination switch (lamplight part)
2. Air outlet 9. Fan control switch 16. Combination switch (wiper and washer part)
3. Danger alarm lamp switch 10. A/C and heater operation control switch 17. Ignition lock
4. Storage box 11. A/C switch
5. Ashtray 12. Indoor and outdoor air cycle switch
6. Cigarette lighter 13. Combination instrument
7. MP3 radio 14. Sundries box

3-2
 Structure description and operation(old cab)
Layout of control area (status 3)

1. Plug 8. A/C and heater change-over switch 15. Sundries box

2. Air outlet 9. Fan control switch 16. Combination switch (lamplight part)
3. Danger alarm lamp switch 10. A/C and heater operation control switch 17. Combination switch (wiper and washer
4. Storage box 11. A/C switch part)
5. Ashtray 12. Indoor and outdoor air cycle switch 18. Ignition lock
6. Cigarette lighter 13. Combination instrument 19. Plug
7. MP3 radio 14. Center console key switch

3-3
Structure description and operation(old cab)
Layout of control area (status 4)

1. Cup holder 7. Middle air outlet 13. Wiper washed and exhaust brake switch
2. Side air outlet 8. PM3 14. Cigarette lighter
3. Plug 9. Combination switch 15. Headlight adjustment control switch and hazard alarm switch
4. Combination instrument 10. Indoor and outdoor air cycle switch 16. Heater and air conditioner
5. Storage box 11. Steering wheel 17. Ashtray
6. Plug 12. Ignition Switch/Steering lock 18. Glove box

3-4
 Structure description and operation(old cab)
Layout of control area (status 5)

1.Driver side air outlet
2.Dashboard and control panel
3.Passenger side air outlet
4. Radio
5. Heating air conditioning controller 9. Brake pedal
6. Transmission joystick 10.Combination switch right handle
7. Cigarette lighter 11.Combination switch left handle
8. Acceleration pedal 12. Clutch pedal
13. Steering wheel

3-5
Structure description and operation(old cab)
Layout of control area (status 6)

1. Multi-functional steering wheel 7. Air outlet 13. Ashtray

2. Combination switch 8. Storage box 14. Cigarette lighter
3. Cup holder 9. Radio 15. Piano-key switch
4. Air outlet 10. Storage box 16. Danger alarm switch
5. Defroster vent 11. Glove box 17. Ignition lock
6. Combination instrument. 12. A/C heater knob

3-6
Structure description and operation(old cab)
Layout of control area (status 7)

1. Left-front power window switch 6. Cigarette lighter 11. Ignition lock

2. Air vents 7. Only vehicular terminal 12. Center console key switch
3. Danger alarm lamp switch 8. Combination instrument 13. Cruise switch
4. Storage cell 9. Storage box 14. PTO control switch
5. Ashtray 10. Storage box

3-7
Structure description and operation(old cab)
Layout of control area (status 8)

1. Front left electric window switch 6. Cigarette lighter 11. Center console key switch
2. Air outlet 7. Only vehicular terminal 12. Cruise switch
3. Danger alarm lamp switch 8. Combination instrument 13. PTO control switch
4. Storage box 9. Storage box
5. Ashtray 10. Ignition lock

3-8

Door
Door switch
Door outside
Push down the door button along the
right arrow direction shown in the
figure and pull out the handle along
the left arrow direction to open the
door.
Structure description and operation(old cab)
Door inside Lock door
Indoor handle
From the outside of vehicle
Lock
Unlock
Pull the door inner handle along the
arrow direction shown in the figure
Turn the key counterclockwise to
to open the door.
lock the door; turn it clockwise to
Danger: after the door is closed, unlock the door.
recheck it, as it is very danger when
the vehicle runs with the doors
semi-closed.
3-9
Structure description and operation(old cab)
From the inside of vehicle
Unlock
Lock
Press the lock button to lock the door.
After that, the door cannot be opened
neither from inside of cab nor from
outside by pulling the door handle.
Uplift the button to unlock the door.
Rotate along the arrow direction the
adjustment lever on the left side of
the seat to adjust and fold the seat
backrest.
3-10
Seatbelts the belt slowly from the retractor,
cross the belt from the area between
shoulder and neck over an
3-point type appropriate position of the chest, and
insert the belt tab into the buckle on
the other side to ensure secure lock.
Adjust the seatbelt to own comfort.
Insert to secure The two-point seat belt is fitted for
Push down to
release the middle seat. Cross the belt over
the hip and insert the belt tab into the
buckle on the other side to ensure
secure lock. Adjust the seatbelt to
own comfort.
2. Release of seat belt
To release the seat belt, push down
the button on the buckle. The seat
belt will retract automatically.
Caution: Ensure the seatbelt is not
Seatbelts are configured for driver twisted and rubbed by hard edges.
seat, passenger seat and middle seat. Prevent the seatbelt from getting
contaminated by chemical products
1. Fastening of seatbelt and battery acid liquid.
To use three-point seatbelt, pull out
 Structure description and operation(old cab)
Caution: One seatbelt is only for
one person.
Caution: The whole seatbelt needs
replacing after it experiences great
impact load or any part of it is faulty
and damaged.
Caution: Replace the seatbelt if the
retractor is jammed.

3-11
Structure description and operation(old cab)

Instrument cluster (status 1)

1. Speedometer 3. Double-pointer air pressure gauge 5. Right steering lamp

2. LCD screen 4. Left steering lamp 6. Indicator and alarm lamp

3-12
 Structure description and operation(old cab)
Instrument cluster (status 2)

1. Speedometer 3. Dongfeng logo 5. Right steering lamp

2. LCD screen 4. Left steering lamp 6. Indicator and alarm lamp

3-13
Structure description and operation(old cab)
Instrument cluster (status 3)

1. Tachometer 4. Right turn signal / hazard warning 7. Water temperature gauge

indicator
2. Left turn signal / hazard warning 8. LCD screen
indicator 5. Speedometer
9. Oil gauge
3. Indicator light 6. Clear/Fault Code Page Button

3-14
 Structure description and operation(old cab)
Instrument cluster (status 4)

1. Water temperature gauge 5. Speedometer 9. Indicator light and warning light

2. Fuel gauge 6. LCD screen 10. Mileage subtotal clear
3. Turn signal indicator 7. Engine tachometer 11. Backlight adjustment knob
4. Speedometer 8. Double needle barometer

3-15
Structure description and operation(old cab)
Instrument cluster (status 5)

1. Indicator and warning lamp 4. Speedometer

2. Engine tachometer 5. LCD
3. Steering indicator 6. Background light knob

3-16

Indication and warning indicator
1.Left turn signal indicator lamp
2.Low oil level indicator
3.Door-open indicator
4.High beam indicator lamp
5.Front fog indicator
6.Rear fog indicator
7.Low beam indicator lamp
8.Driver seatbelt indicator
9.High coolant temperature
indicator
Structure description and operation(old cab)
10.Right turn signal indicator lamp 18. EPS indicator 26.Daytime traveling indicator
11.Low engine oil pressure indicator 19.Co-driver seatbelt indicator 27.Oil-water separator
indicator
12.Driver warning indicator (diesel20.EBD indicator lamp
engine) 28.Exhaust brake indicator
21.GPF regeneration indicator
lamp
13.Brake fault indicator (diesel engine)
29.Engine malfunction
14.Warning indicator of low adblue level22.MIL indicator
indicator lamp
(diesel engine)
23.Warning indicator of brake
30.Intake preheating indicator
15.Parking brake indicator shoe wearing (optional)
lamp
16.Airbag indicator lamp 24.ABS indicator lamp
17.Charging indicator 25.Cruise indicator lamp
3-17
 Structure description and operation(old cab)
Speedometer Instrument cluster LCD subtotal can be reset when long
screen pressing the reset/fault code page
up/down button for 2s above. When
short pressing (within 2s) this button,
the main interface, interface II,
interface III and interface IV can
appear alternatively. If the engine has
no failure, the interface II will not
appear.
The fuel gauge is used to indicate the
approximate fuel level in fuel tank.
Main interface The pointer of fuel gauge can vary
The speedometer indicates the
slightly when applying brake,
driving speed of the vehicle in unit
Speed indication turning, stepping accelerator pedal or
of km/h.
Oil level Water temperature going uphill/downhill. The alarm
indication indication
1/2 mark position
zone of fuel level is 1/8.
Alarm zone 1/8
Caution: The fuel shall be refilled
before the fuel gauge indicates zero.
Urea tank liquid level
indication
Total mileage
The water temperature gauge is used
to indicate the temperature of coolant.
The coolant temperature will vary
with the atmosphere temperature and
The main interface is default running condition. The water
interface, on which the mileage temperature alarm limit is 100°C.
3-18

Caution: when the coolant gauge
pointer goes beyond the normal
range, please immediately check if
its warning indicator lights up; if so,
please pull over the vehicle to safety
as soon as possible. (Driving with
the engine overheating could
severely damage it). If the indicator
does not light up, please keep
driving.
The engine tachometer indicates the
real-time speed of engine, expressed
in r/min. In no case can the engine
speed exceed critical range.
Display interface II
Structure description and operation(old cab)
In the case of engine fault, the fault
code will be displayed automatically.
When the interface II is displayed, it
is allowed to rotate the button to
page up/down the fault code. If
rotating left, view the next fault code;
if rotating right, view the previous
fault code. When short pressing the
button (within 2s), return to the main
interface.
Display interface III
Subtotal mileage
Total fuel consumption
Display interface IV
Instant fuel
consumption
Average fuel
consumption
When the interface IV is displayed,
press the button for 2s below to
return the main interface.
When the vehicle speed is greater
than 30km/h, the instant fuel
consumption per 100 kilometer will
be indicated. However, the indicated
value cannot exceed 20L/100km.

Fault code

Prompt message
When the interface III is displayed,
Which fault code
Total fault codes press the button for 2s above to reset
the mileage subtotal.

3-19
Structure description and operation(old cab)
Fuel gauge and coolant used to indicate the temperature of The air pressure gauge is of double
thermometer engine coolant and starts to work pointer type to indicate the air
when the key switch is at ON. . On pressures for front axle brake system
Oil level Water temperature
the dial, the marker C means the low air reservoir and rear axle brake
indication indication temperature and H the high system air reservoir respectively. The
temperature, and thus the ideal indication range of the air pressure
temperature is that the pointer is at gauge is 0~12×100kPa.
the middle of two scales. . When the pointers are within the red
Caution: When the coolant is too zone, it's prohibited to start up the
Mileage subtotal
hot, its indicator will light up, and vehicle for driving.
Total mileage
if you continue to drive
①Startup homepage
Engine tachometer
Double-pointer air pressure
By default, the LCD shows the fuel
gauge and coolant thermometer. The gauge
fuel gauge (at left) is used to indicate
how much the fuel is left in the fuel
tank and starts to work when the key
switch is at ON. . Additionally, F on
its dial means the fuel tank is full and
the E means the fuel runs out.
Therefore, when the pointer
approaches the E, please refuel the
tank as soon as possible.
Coolant thermometer (at right) is Engine tachometer pointer shows the

3-20

instantaneous RPM of engine. Red
area on gauge means the critical
range of engine rpm which engine is
prohibited to run up, and thus, the
engine RPM should be kept between
the critical range. Warning RPM of
Liuzhou Automobile engine is
6000r/min.
Indicator and warning lamp
Intake preheating indicator lamp
This indicator lamp turns on when
the key is rotated to position ON.
This indicator lamp turns off when
the engine is preheated to a certain
Structure description and operation(old cab)
temperature, in which case the equipped)
engine can be started.
Door indicator(If equipped)
With the daytime running lamp in
working, its indicator will light up.
Conditions to turn on the daytime
This indicator is used to show check running lamp: engine RPM is higher
all doors are closed up. If any door is than 400rpm or the control signal of
not closed in place, this indicator and daytime travel lamp is valid.
the corresponding door indicator
MIL indicator(If equipped)
light up to alert the driver, and goes
out when the door is closed up.
Cruise indicator(If equipped)
In case of engine faults, the MIL
lights up.
When you press the cruise button, ABS indicator lamp(If equipped)
this indicator lights up, meaning the
vehicle under the cruise status. When
you depress the brake pedal or turn
This indicator is used to show the
off the cruise button, its indicator
ABS working status. When a door is
will go out.
opened and vehicle is in
Daytime traveling indicator(If self-checking, the ABS indicator
3-21
Structure description and operation(old cab)
lights up and then goes out. However, Tail brake detection indicator High-beam indicator
if it does not light up or does not lamp (If equipped)
goes out for a few seconds, it means
the ABS system fails.
Danger alarm lamp switch

This lamp will be on when the

If one of the combination lamps vehicle headlamp is in high beam;
(without turn signal and reversing when the overtaking lamp is
lamps) are faulty, this warning lamp operated, this lamp will also be on.
is on.
When the switch of hazard warning
lamp is turned on, all the turn lamps
light up and flash at the same time to
alert other vehicles.

3-22
 Structure description and operation(old cab)
Battery charging/ discharging Parking brake indicator Indicator of seat belt
indicator

Pulling the parking brake lever could

When the ignition switch is switched light its indicator, telling the driver When the key is turned to ON, the
to ON, this indicator will be lit. After that the vehicle is braked. Releasing indicator flashes for 7 seconds to
engine is started, generator could the lever could have this indicator go remind the driver and passenger of
charge the battery, and this indicator out. At vehicle moving away, check wearing seat belt.
will go out. During travel, in case of whether this indicator is lit or not. Position indicator lamp
any failure happening to the charging
system, this indictor can also be lit.
Caution: when this indicator is lit,
do not have the vehicle run, which
otherwise could deteriorate the
battery and shorten its useful life.

3-23
Structure description and operation(old cab)
This indicator lamp turns on when
the position lamp is turned on.
Exhaust brake indicator lamp
The exhaust brake indicator lamp
turns on when the exhaust brake
system is working.
3-24
Brake failure indicator Rear fog lamp indicator lamp
This indicator lamp turns on after the
The indicator is illuminated when the
rear fog lamp switch is turned on.
engine is working, reminding the
driver to check brake fluid level. If Defrost indicator
the level is below the MIN, add
brake fluid.
When the vacuum booster is if low
vacuum, the brake indicator is
illuminated.
The indicator is illuminated when
defrost is switched on.

Engine malfunction indicator lamp
This indicator lamp turns on in event
of any malfunction of the engine.
Please observe the trouble code.
Low beam
Structure description and operation(old cab)
When the combined light switch is Steering indicator
shifted to low beam, the indicator is
illuminated.
Front fog lamp
The indicator tells operation
condition of steering light. When the
bulb of steering light is damaged, the
indicator changes frequency to warn.
The indicator is illuminated when the
front fog lamp is powered on.
3-25
Structure description and operation(old cab)
Indicator of drying air
The indicator is illuminated when the
air drying is switched on.
Coolant temperature warning light
When the coolant temperature is
3-26
high, the indicator is illuminated. prohibited to continue the driving of
Warning indicator of low oil the vehicle.
pressure Warning indicator of oil-water
separator
This lamp turns on when the key
switch is rotated to position ON and When the water in water-oil
turns off after the engine is started. separator has accumulated to certain
In event of abnormal drop of engine amount, the switch is powered on to
oil pressure during the running of the illuminate the indicator.
engine, this lamp will turn on for
warning.
Caution: Too low engine oil
pressure will burn down the engine.
Caution: If this warning lamp turns
on due to low engine oil pressure, it’s
 Structure description and operation(old cab)
Warning indicator of fuel level Adjustment of seat Backrest adjustment of
driver’s seat
Tilting adjustment of driver’s
seat

The indicator shows oil left in the

vehicle. When the door is open, the
vehicle performs self-inspection and
indicator is illuminated for seconds
and then goes off. If the indicator is
illuminated when the engine is
started, it indicates less oil left in the
vehicle.
Push the rod in front and below the
seat to the direction indicated by the
arrow to move the seat forward and
backward till you can easily depress
the pedal to the end. Release the rod
and lock the seat at the position.
Danger: Do not adjust the driver
seat longitudinally during the driving
of the vehicle.
Lift the lever at the left side of seat
to have the backrest to move the
comfortable position for holding of
steering wheel; release the adjusting
lever to have the backrest locked at
the needed angle.

3-27
Structure description and operation(old cab)
Adjustment of front passenger Adjustment of middle seat locking the doors.
seat backrest backrest

Push the lower control lever on the

right of seat as per the arrow Vehicle keys
direction to lower the seat backrest.

1. Indicator lamp 2. Lock

3. Unlock
Remote unlocking
Turn ignition lock to OFF, close all
doors and press remote unlock
This vehicle is equipped with two button;
keys for controlling the ignition lock
and fuel tank, and for unlocking or Remote locking

3-28

Turn ignition lock to OFF, close all
doors and press remote lock button;
Vehicle searching
All doors are locked and press lock
button;
Reminding of door unclosed
Turn the ignition lock to OFF, any
door is open, press remote lock
button; however the doors are not
locked;
Turn the ignition lock to OFF, any
door is open, press remote unlock
button and all doors are unlocked;
Manual locking and unlocking
Manual pull the door lock button on
the driver’s side to unlock all doors.
The steering light does not flash.
Manual push the door lock button on
the driver’s side to lock all doors.
The steering light does not flash.
Manually turn the lock button on the
Structure description and operation(old cab)
driver’s side anti-clockwise to
unlock all doors. The steering light
does not flash.
Manually turn the lock button on the
driver’s side clockwise to lock all
doors. The steering light does not
flash.；
Other
The remote control does not work
when the ignition lock is turned to
ACC or IGN.
Ignition lock
Lock
LOCK: only at “LOCK” can the
key be inserted.
ACC: with engine no running, to use
any accessories (such as the radio,
wiper and cigar lighter), turn the
switch to ACC.
ON (engaged): After the engine is
stared, the ignition key could
automatically bounce back to ON
from START, engine running
normally. With the engine running, it
is prohibited to turn this key to any
other position.
R or H (Preheating, if equipped): To
start the engine in cold season, rotate
the key to preheating position to run
the preheating plug. The preheating
time can be manually controlled.
START: turn the key to this position
to start engine. At the START, when
the key is loosened, it will
automatically return back to ON.
Caution: With engine running, it is
3-29
Structure description and operation(old cab)
prohibited to turn the ignition key to Lighting switch
the START, otherwise the starter will
be damaged. Only after the engine is Lighting switch
completely started, can the engine be st
position
1
started again.
Caution: when turning the key from
ACC to LOCK, press the key at
PUSH, instead of turning to LOCK
2nd position
directly; otherwise the key may be
damaged.
Combined switch Forward rotate the end of combined
switch lever, lighting the following
(lighting part) lamps:
This switch is combination for front
position lamps, rear position lamps,
headlamps, instrument lighting,
license plate lamp, overtaking lamp
as well as beam change and turn
signal indicator lamps.

3-30
 Structure description and operation(old cab)
○ Means ON and × OFF direction lamp
Side  Backward moving the lever could flash the left
Front Rear Licens Licens Front Rear
Lever Headla
Positio positio e plate e plate
Instrume
clearan clearan
mark direction lamp
position mp nt lamp er
n lamp n lamp lamp lamp ce lamp ce lamp
lamp Dimming switch
OFF × × × × × × × × ×
1st Dimming switch
× ○ ○ ○ ○ ○ ○ ○ ○
position
2nd Up
○ ○ ○ ○ ○ ○ ○ ○ ○
position

Direction signal lamp

Down

Direction signal lamp

Front Change the beam by pulling the combination switch lever

upwards and downwards, that is, to switch between high
and low beams.
Rear

Forward or backward moving this lever could flash the

left or right direction lamp. At the same time, the left or
right direction indicator will flash.
 Forward moving the lever could flash the right
3-31
Structure description and operation(old cab)
Combined switch (wiper and washer) Caution: Individually operating the wiper in sunny days
will scratch the windscreen. Make sure to use along with
Wiper the washer.
Caution: do not activate the washer in case of lack of
washer fluid, which otherwise could damage to the
washer motor.
Washer
Intermittent Caution: the freezing point of washer fluid should be less
Low than the ambient temperature where the vehicle works by
3~5℃.
High
Elevation switch of power glass

Pull backward the combination switch lever to run the

wiper. Wiper has three speed modes: intermittent, low
speed and high speed.
It is needed to wipe the windshield clean
 Lowering the end of washer switch lever could
activate the washer, washer fluid continuously
spraying on the glass and wiper operating to clean the
windshield glass. Press the button to move the glass at the co-driver’s side.
 Releasing the lever end could stop the washer. Window and rear-view switch
 Push the lever forward to the stop to turn off the Power window lifer at driver side
wiper.
3-32
 Structure description and operation(old cab)
Lock switch of power window:
Upon pressing the lock switch, only the driver’s window
lifts up; press it again to release the lock.
Power window lifter switch:
Power window lifting at driver side is divided into
window lifter switch at driver side and the one at
passenger side, respectively controlling the two windows.
Press the window lifter forwards, lowering the
corresponding window and release it, stopping the
lowering.
Press the window lifter backwards, lifting the
Lock Switches corresponding window and release it, stopping the lifting.
Window lifter The lifter switch at driver side has the only inching lifting
switch at driver side
gear and the inching and automatic lowering gear. The
lifter switch at passenger side only inches the window up
or down.
Rearview adjusting switch:
Window lifter
switch at
passenger side

3-33
Structure description and operation(old cab)
This switch is used to adjust the external rearview mirrors
at driver and passenger sides. With the switch at gear L,
MIRROR switch is available to adjust the external
rearview mirror at driver side
upwards/downwards/leftwards/rightwards; with the
switch at gear R, MIRROR switch is available to adjust
the external rearview mirror at passenger side
upwards/downwards/leftwards/rightwards;
Power window lifting at driver side
3-34
The power window switch at passenger side is used to
control the passenger’ window to go up or down.
Danger: be careful while the window goes up, as
carelessness may lead to the personal injury (such as
bruise or clothes jamming), and ensure there is no
obstacles on the way of window closing. Besides, if the
window glass touches any object, it is a must to have the
window move reversely.
Danger: driver must ensure the power window lifter
switch is correctly used by passengers.
 Structure description and operation(old cab)
Headlamp dimmer switch Radio/MP3 player

The headlamp beam changes with the different loads and 1. Left knob 2. Display screen
the cab’s horizontal positions and thus needs to be 3. Right knob 4. USB interface
adjusted to make sure the accuracy of illumination. 5. CLK key 6. APS key
0: upward moves the headlamp beam; 7. Back key 8. Forward key
9. MODE mode 10. MUTE mode
－: normal, unnecessary to adjust it
Left knob: press the knob for start or shutdown; turn
1, 2, 3: downward moves the headlamp beam;
left/right the knob to adjust sound volume.
Right knob: under radio mode, turn the knob to adjust the
radio frequency; under MP3 mode, turn the knob to select
the music to be played; under clock adjustment mode, turn
the knob to change figure; press the knob to enter tweeter,
bass and balance menu and turn the knob to change figure.

3-35
Structure description and operation(old cab)
CLK key: this is clock adjustment key; press the key to
enter hour and minute adjustment majeure or the loss of MP3 memory. ON position
mode. At this time, the hour or Caution: Please use legitimate audio The dome lamp will be on regardless
minute will flicker. Turn the right tracks. of open or closed doors.
knob to change the desired figure.
APS key: this is save key. Under Cab ceiling lamp Cab sunroof
radio mode, press the key to
automatically search and save the
radio program from low to high
frequency.
MUTE key: press this key to enter
mute mode.
MODE key: press this key to switch
between FM radio/USB play.
Danger: The driver shall not listen O position
to the music by earphone during
driving. The ceiling lamp will turn on
whenever a door is opened and turn To introduce outside fresh air into
Caution: Please take out the MP3 off after all doors are closed. the cab, operate the sunroof switch
memory and battery when it's not in along the arrow direction to open and
use. OFF position tilt the sunroof.
Caution: Our company will not be The dome lamp will not be on
liable for the damages due to regardless of open or closed doors.
man-made malfunction or force
3-36

A/C system (status 1)
Vent position
Knob
Rotate the knot could adjust the
air vent direction.
A/C
1. Working condition selection
2. Fan switch
3. A/C – heater changeover switch
Structure description and operation(old cab)
4. A/C switch
5. Indoor air cycle switch
1. A/C switch
To turn on the A/C, press this
switch, indicator lighting up that
means the power is on.
2. Fan switch
5 positions of 0, 1, 2, 3, and 4 are
configured for the fan switch.
Position 0 means the fan is off.
The fan blowing rate can be
increased in sequence from
positions 1 to 4.
3. A/C-heated air switching
If A/C is required, move this
switch to blue mark; if heated air
is required, move it to red mark.
4. Operating mode selection
switch
—Head air supply
—Feet air supply
—Head and feet air supply
—Internal heating and
window defrosting
—Window defrosting
5. Internal circulation switch
Press this switch, quickly
refrigerating or heating the
internal air and insulating the
external odor or dust. But, the
external circulation mode should
be changed to as soon as you have
chance, so as to refresh and
defrost the internal air.
Caution: The heater uses the
engine water temperature to heat
the air thus temperature of heated
air will not be high in case of low
water temperature.
Caution: At engine shutdown or
idling, do not operate the heater or
A/C for too long; otherwise
normal running is affected due to
excessive consumption of the
3-37
Structure description and operation(old cab)
battery. A/C system (status 2) Mode knob
Caution: During continuous
Heater controller
running, please downshift to
increase engine rotating speed; in
case of running uphill for long,
note to downshift to reduce engine
burden.
Caution: An internal of 2~3min
shall be applied between turning
on and off the A/C, which
otherwise shortens the compressor 1. Face-blowing gear: blow air
life. to your face
2. Face-blowing and
Caution: Even in winter, turn on 1. A/C Switch
feet-blowing gear: blow air
the A/C every one month to 2. Temperature control knob to your face and feet.
prolong the A/C system’s life.
3. Fan and internal/external 3. Foot-blowing gear: blow air
circulation knob to your feet.
4. Mode knob 4. Foot-blowing and defrosting
and defogging gears: blow
air to your feet and
meanwhile defrost and defog
the windows.
5. Defrosting and defogging
gear: defrost and defog the
window glasses.
3-38

Fan and internal/external
circulation knob
Internal circulation gear; fan is
turned off and the heater system is
in the internal air circulation state.
Five-gear at left side: adjust the
fan RPM, namely the air-blowing
strength, which is divided into
five gears: the wider the
schematic is, the faster the wind
speed, and the heater system is in
the internal air circulation state.
Structure description and operation(old cab)
External circulation gear: after fan (compressor) starts to work.
turned off, the heater system is in OFF (the button pops up and its
the natural ventilation state (the indicator goes out): refrigerator
external fresh air comes in). does not work.
Five-gear at right side: adjust the
fan RPM, namely the air-blowing
Temperature control knob
strength, which is divided into
five gears: the wider the
schematic is, the faster the wind
speed, and the heater system is in
the internal air circulation state
(the external fresh air comes in)
A/C button (A/C Switch)
Left half zone (blue area):
refrigeration zone
Right half zone (red area):
warming zone
Warming mode
To activate the warming function,
perform the following steps:
On (it is pressed down and its
1. Turn the temperature knob to
indicator lights up): refrigerator
3-39
Structure description and operation(old cab)
the warming zone. external/internal circulation fan and then press the A/C
2. Turn the fan and knob to other gears than the switch; otherwise, the
external/internal circulation “external circulation gear” cooling function cannot be
knob to other gears than the and “internal circulation started (indicator on A/C
“external circulation gear” gear”. switch does not light up).
and “internal circulation 3. Press the A/C button 2. To turn off the A/C, firstly
gear”. (lighting up the indicator) press the A/C switch (the
If you want to increase If you want to increase indicator on A/C switch goes
temperature, the following temperature, the following out) and then turn off the fan
measures could be taken. measures could be taken: after 2-3min. However if the
fan is turned off firstly, the
1. Turn the temperature knob to 1. Turn the temperature knob to A/C switch is also powered
the rightmost end, max. the leftmost end, max. off at the same time.
warming position. refrigeration position.
3. For restarting after the A/C
2. Turn the fan and 2. Turn the fan and compressor is turned off,
internal/external circulation internal/external circulation wait 3-5min, which
knob to the higher gear at knob to the higher gear at otherwise may affect the
right of “internal/external right of “internal/external service life of compressor.
circulation gear”. circulation gear”.
Naturally ventilation mode
Refrigeration type 3. Press the internal/external
circulation button (lighting To activate the natural ventilation
To activate the cooling function, function, perform the following
perform the following steps: up the indicator)
steps:
1. Turn the temperature knob to Caution:
1. Turn the temperature knob to
the refrigeration zone. 1. To activate the cooling the refrigeration zone.
2. Turn the fan and function, firstly start up the
2. Turn the fan and
3-40

internal/external circulation
knob to the external
circulation gear.
Windshield defrosting and
defogging
To defrost the windshield, turn the
temperature knob to the warming
zone, the mode knob to the
defrosting and defogging gear,
and the fan and internal/external
knob to the highest gear of
internal circulation.
To defog the windshield, turn the
temperature knob to the cooling
zone, the mode knob to the
defrosting and defogging gear, the
fan and internal/external
circulation knob to the highest
gear of internal circulation.
Caution: Heater makes use of
engine coolant heat to warm up
the air. Thus, when the coolant
temperature is not high, the
out-sent air is not warm enough.
Structure description and operation(old cab)
Caution: With the engine not turned on and if released, it is
running or idling, do not use the turned off.
heater for a long time; otherwise,
battery will consume so Levers, steering wheel
excessively as to affect the and accessories
traveling. .
Gear lever
Caution: Before running at low
speed for a long time, please do
shift the transmission to the lower
gear and increase the engine rpm;
before running on the long uphill,
shift to the lower gear, so as to
reduce the engine load.
Caution: Rotate the temperature
knob to the cooling zone, and the
decreased amount of air comes To shift the gear, firstly depress
out. In such case, press the the clutch pedal to the end. To
internal/external circulation knob shift the forward gear to the R
or increase the air volume. gear or R gear to forward gear,
Caution: For the internal warming, stop vehicle completely.
the A/C switch should be turned At R gear, the reverse lamp will
OFF to increase the heating be lit. At the same time, the
efficiency and reduce the engine’s buzzer will alarm, alerting the
energy consumption; besides, the other road users.
A/C switch, if pressed down, is
3-41
Structure description and operation(old cab)
Gear layout is dependent on the
vehicle model.
Parking brake handle
1．Forward to release
2. Backward to brake 3. Pull up
After the vehicle is stopped
completely, pull backward the
handbrake handle to locking
position. To release the parking
brake for startup, pull up the
locking sleeve of the handle and
then push forward the handle (If
the air pressure is too low, the
parking brake can’t be released).
Caution: park the vehicle at the
as flat ground as possible.
3-42
Adjustment of steering Multi-functional steering
wheel wheel
Adjust
Pull up
With the lock lever released, the
steering wheel could forward or
backward incline by up to 15°and Volume adjustment of
upward or downward move by the multimedia
max. travel of 30mm. Before
adjusting the steering wheel,
properly adjust the seat suitable
for the driver stature. After the
steering wheel has already fine
tuned, lock the steering wheel
adjusting mechanism to prevent it
from varying during traveling.
Danger: do not adjust the steering
wheel during travel.
 Structure description and operation(old cab)
1. Multimedia volume change MP3 mode and the previous Click it to hang up the phone at
2. Multimedia channel/music channel at the radio mode. the phone call mode and to mute
change Press  with the handle in the the phone at the multimedia mode.
3. Answer button of bluetooth front and hold it, increasing the Cruise (if equipped)
telephone frequency continuously at the
radio mode; release it, stopping at
4. Changeover of multimedia the current frequency.
sound source mode
Click ▽ with the handle at the
5. Bluetooth telephone
rear, selecting the previous song at
hang-up/mute
MP3 mode and the previous
Volume adjustment of channel at the radio mode.
multimedia
Press ▽ with the handle in the
Click +/- to turn up / down the front and hold it, decreasing the
volume by one gear. frequency continuously at the
Press +/- to continuously turn radio mode; release it, stopping at
up/down the volume, and release the current frequency. Conditions to activate the cruise
it to stop the volume Changeover of multimedia • There is no braking or clutch
turning-up/-down. sound source mode pedal action signals
Short press mute key 5 to mute Click SRC with the handle down, • The cruise OFF is not
the multimedia. switching the multimedia between pressed.
Multimedia channel/track MP3/radio/AUX-IN modes.
• There is no faults related to
adjustment Bluetooth phone the cruise, electronic throttle,
Click  with the handle at the In case of incoming call, click the brake and clutch.
front , selecting the next song at bluetooth phone to answer it.
3-43
Structure description and operation(old cab)
• Running at the third gear or
higher at the speed more than
40 km/h.
• Complete-vehicle voltage is
between 9V and 16V.
After the above conditions are met,
uplift the ON for the first time to
enter Standby Enable and uplift it
again to enter the Cruise ON.
Cruise working status
1. Uplift or press the ON button
for the first time to increase
or decrease the vehicle speed
by 2km/h.
2. Uplift or press the ON button
for 1.75s or longer, which is
identified as the long
pressing by ECU, activating
the Accelerate ( continuous
acceleration) or Decelerate
(continuous deceleration)
mode, and thus the vehicle
speed increases or decreases
by 2km/s of acceleration or
deceleration.
3-44
3. Max. cruise speed should not
exceed 100KM/H (set by
customer requirements).
Press the ON button or click
it for a few times, and the
target cruise speed drops to
40KM/H; besides, the cruise
exits when actual vehicle
speed drops to 40KM/H.
4. In the cruise state, depress
the brake or clutch to quit the
cruise; however, when the
cruise activation conditions
are met, press the RES to
cruise at the speed at which
the last cruise exit. In such
case, uplift the ON button to
cruise at current speed.
5. During a cruise, press the
OFF button to directly quit
the cruise and meanwhile
delete the cruise speed stored
in the ECU. In such case, you
cannot enter the cruise by
pressing the RES.
6. In a cruise, the vehicle speed
should stay unchanged, with
±1.5km/h of fluctuation
range.
7. In a cruise, depress the
accelerator pedal to overtake
and after that, the cruise
could still work if the cruise
conditions are met.
If you uplift the ON button
once, the vehicle will cruise at
the current speed. Moreover,
upon the ignition switch is
turned off, the cruise function
will be deactivated, and the
cruise speed stored in ECU
will be deleted. Besides, you
cannot enter the cruise by
pressing RES.
8. If the cruise activation
conditions are met and the
cruise indicator lights up
when the cruise is turned on,
the indicator will go out after
the cruise deactivated.

How to quit cruise
• Depress the brake, clutch or
accelerator pedals, quitting
the cruise and entering the
Standby Enable mode.
• There is something wrong
with the cruise and electronic
valves.
• Depress the brake,
accelerator or clutch, quitting
the cruise and entering the
Standby Enable mode.
• Press the OFF button.
• Transmission gear is at the
second gear or lower.
• Vehicle speed is below
40KM/H.
• Voltage is not within 9-18V.
• At the extreme conditions,
the basic software of ECU
fails.
Structure description and operation(old cab)
PTO functions (if equipped)
Conditions to activate the PTO
• There is no brake or clutch
signals.
• Transmission is at the neutral
gear.
• Engine idles.
• There is no faults occurring
to the cruise /PTO control
switch.
PTO working status
1. Click the ON/V two times to
enter PTO status, and engine
RPM increases to 1500r/min.
2. Click ON/V+ or V-, to
increase or decrease the
engine RPM by 100r/min
(the calibrated test data
prevails) at the interval of not
less than 0.5s ( ECU
responds only once if less
than 0.5s).
3. Press ON/V+ or V- for 0.5s
or longer, which is identified
as the long pressing by ECU,
and thus engine RPM
increases or decreases by
100r/min (the calibrated test
data prevails); release it to
stay the RPM at the current
value. Besides, the RPM
regulations should be within
the calibrated range, with
2000r/min as the top limit.
4. Click the OFF to deactivate
the PTO function.
5. After the PTO is activated, it
3-45
Structure description and operation(old cab)
cannot be recognized that Courtesy lamps (door Interior rearview mirror
two buttons or more are lamps)
pressed at the same time,
therefore, the current PTO
setting is kept unchanged.
PTO exiting
• Just depress the brake, clutch
or accelerator pedals.
• Press the OFF. Courtesy lamps Interior rearview mirror could be
As for the cigar lighter, it could adjusted to be at any angle.
pop up to the original position Door-opening warning
after glowing, so that you can pull They are mounted on the door
guards at the sides of driver and function
it out, and after using, put it
back. . passengers for the steps If small lamp is ON, any door is
illumination and controlled with opened and ignition lock is OFF,
Danger: the cigar lighter cannot
the door switch: when a door is the beeper in the comprehensive
be connected for a long time, and
opened, the courtesy lamp lights alarm sounds out to alert the
must be pulled up manually if
up; when a door is closed up, it driver of turning off the lamp
unable to pop out by itself.
goes out. when leaving.
Caution: Please use the genuine
Dongfeng cigar lighter and do This switch has four gears: 0, 1, 2,
not change it at will; otherwise 3, 4, 5.
we will take no responsibility for Gear 0 means the ex-factory
fire caused by cigar lighter. position, with lamp voltage at 1V.
Gear 1 means the lamp voltage at

3-46

3V gear 2 at 5V;
Gear 3 means the lamp voltage at
7V gear 4 at 9V;
Gear 5 means the lamp voltage at
11V
Micro-wave window
The microwave window is set the
middle-upper part of windshield,
with its position and range shown
below:
Towing hook
This vehicle use the spin-on
towing hook.
How to use it is shown below:
Take out the hook out of the spare
part package. Screw the hook into
the mounting base of bumper until
Structure description and operation(old cab)
the end, and then it is ready to use.
After work, screw the hook
reversely off the base and put it
into the spare part package.
Spare tire lock
How to use:
The spare tire lock is at the
rear-center of frame.
1. After inserted with the key,
the spare tire can be directly
taken down to access its
connecting rod.
2. With the key in the spare tire
lock, the lock housing can be
sleeved into the connecting
rod of spare tire, and then
pull out the key to lock the
spare tire.
OBD port
ECU data is read from the OBD
port at the left-lower side of driver,
as shown in the above figure. .
Connect the diagnostic apparatus
to the OBD port, so as to read the
VIN according to the operational
illustration of diagnosis apparatus.
The diagnostic apparatus, as long
as it meets the engine
communication protocol, could
read the vehicle information, and
3-47
Structure description and operation(old cab)
if you have any question, please
consult the Dongfeng-authorized
service station.
Front hood
Opening of front hood (Manual)
1. Slightly pull the unlocking
panel at the driver’ side, half
opening the hood.
2. Move the lock handle at the
Inside-middle-upper side of
hood towards the right, and
gently rotate it to fully open
the hood.
Hood closing
Move the inner-middle-upper lock
handle towards the right, and then
3-48
slowly and forcefully press the
hood to lock it.
Rearview mirror (status 1)
Rearview mirror at the side of
driver
1. Main rear view mirror
2. Wide angle lens
The main rearview mirror can
give the visual field far behind the
vehicle but the visual field is
narrow.
Rearview mirror at the side of
passenger
1. Main rear view mirror
2. Wide angle lens
3. Low view mirror
4. Close-proximity mirror
Lower rearview mirror: it can give
the front visual field when starting
and parking.
Close-proximity rearview mirror:
it can give the visual field around
the right body of driver cab.

Rear view mirror (status 2)
Rearview mirror at the side of
driver
1. Main rear view mirror
Rearview mirror at the side of
passenger
Structure description and operation(old cab)
1. Main rear view mirror
2. Wide angle lens
Danger: Do not change the
rearview mirror’ angle while
vehicle is running, which
otherwise is prone to cause traffic
accident.
Rear view mirror (status 3)
Rearview mirror at the side of 1. Main rear view mirror
driver
2. Wide angle lens
3. Close-proximity mirror
Danger: during traveling, it is
prohibited to change the rearview
mirror, which otherwise could
cause the traffic accidents.
1. Main rear view mirror
2. Wide angle lens
Rearview mirror at the side of
passenger
3-49
Structure description and operation(old cab)
Rear view mirror (status 4)
Adjustment
Adjust the exterior mirror to any
angle for maximum visibility
fold
Pushing the exterior mirror to the
inside of the car body, folding the
exterior mirror
3-50
Front view mirror
The front view mirror helps you
see the objects in front of the
vehicle
Cigar lighter
To use the cigar lighter, press the
cigar lighter inward and hold it for
10s. The cigar lighter could
automatically pop out to the
original position after its
resistance wire glows. After that,
put the cigar lighter back to the
original position.
Caution: If the cigar lighter
cannot be lit after 10s, please ask
for help to avoid any other failures.
If the cigar lighter is not used
correctly, vehicle may catch fire.
Therefore, be careful to use the
cigar lighter.
Caution: It’s prohibited to push
down the cigar lighter for a long
time.
Caution: Please use the original
cigar lighter of Dongfeng
Automobile Co., Ltd. and do not
replace at will, otherwise our
company will not be liable for any
fire accident arising thereof.

Ashtray
To use the ashtray, pull it backward.
To clean the ashtray, pull it
backward, meanwhile, press the
tongue at the rear end.
Caution: before leaving the vehicle,
close the ashtray for the sake of
safety.
Structure description and operation(old cab)
Front ceiling lamp control the front ceiling lamp
to be three statuses:
constant-ON, door control or
OFF
If you press the “Constant-ON”
on the door control switch, the
front ceiling lamp lights up and if
you press the “Constant-OFF”, it
goes out (Constant-OFF).
1. Switch of left 4. Position On the position of door-control
read lamp of door switch, the ceiling lamp could
switch
2. Constant-ON light up when the vehicle is
switch 5. Right read unlocked, a door is opened or the
3. Constant-OFF lamp ignition key is unplugged, and
switch switch then goes out 30s after door is
closed up. Besides, upon the
6. Lamp
vehicle is locked or started up, the
housing
ceiling lamp goes out.
Switch of front ceiling lamp has
the left and right read lamp Operations on cab floor
switches and door control 1 In order to repair the engine,
switches. fold up the passenger
1. Left and right read lamps are backrest and remove its trims
controlled with its switch. of left and right buckles, as
shown in the figure.
2. Door control switch could
3-51
Structure description and operation(old cab)

2. Then, open the left and right

buckles of engine cover, as
shown in the figure.

4. Max. load of sling: 80kg;

don’t hold the engine when it
is uplifted.

3. Uplift the seat together with

the engine cover in the
direction shown in figure,
and then hoist the engine
cover hook onto the fixing
support.

3-52

Rear side window
The cab with sleeper is fitted with left and right rear
windows, which can be opened for ventilation.
Structure description and operation(old cab)
Installation / removal of power supply
wire
Frame
Battery
Closely follow the fig. 1-6 to install each pole.
Do not proceed until the pole is tightened and its sleeve
is reliably.
To remove the power supply wire, firstly disconnect the
negative pole of circuit and the No.5 pole.
During use, wire should be avoided to be touched with
the main power switch, frame, battery frame etc.
3-53
Structure description and operation(old cab)
Operation of spare tyre unit Cargo box fence levers
Rear fence levers
Right

Tailgate handle
Push

Tension

The spare tyre is installed at the vehicle rear.

Spare tyre removal
Pull up along the arrow direction the rear fence levers
• Rotate the drive rod counterclockwise using a (each on left and right sides) and then forcibly open the
wrench to lay down the spare tyre. rear fence.
• Take out the bracket and pull out the spare tyre.
Spare tyre stowage
• Stow the spare tyre as per reverse of the removal
procedure.
Caution: Spare tyre must be reliably stowed to prevent
loss.

3-54

Side fence levers
Side gate
handle
Tailgate handle
Open the side fence lever along arrow direction and
then open corresponding rear fence lever to open the
side fence.
Cab tilting
Precaution for cab tilting
• Park the vehicle on ground as flat as possible.
• Pay full attention to the ceiling height and check for
sufficient clearance to the wall ahead.
• Confirm the parking brake is applied.
• Place the transmission shift stick to neutral position.
• If necessary, use triangle chocks to stop each wheel.
Structure description and operation(old cab)
Caution: Organize the scattered objects in the cab and
for items that are easy to fall during tilting, move and
locate them in place.
Tilting mechanism
Operation of cab tilting
Tilting
1. Slightly press the handle A using the right hand and
hold the pulls B and C1 of limiting arm together
using the left hand to disengage the hook H and pin
shaft G and then push upwards the handle A to its
stop.
2. Hold the pull C1 or C2 with left hand and pull the
safety hook D with the other hand until the it is
disengaged with hook housing J. Then tilt the cab.
3. After confirming the clamp plate E rotates
3-55
Structure description and operation(old cab)
downwards and is hitched, rotate the clip ring F to Danger: The clamp ring must be locked whenever the
the slot at the end of clamp plate E from the upper cab is tilted.
position.
Filler cap
Tilting release
Danger: The fuel is inflammable and easy to explode
Release under some conditions. Improper use or operation may
cause scald or other serious injuries. During filling the
fuel, shut down the engine. Do not smoke around the
vehicle and open flame or sparks are not allowed!
Danger: A certain pressure exists in the fuel tank.
Unscrew the filler cap by half a turn and open it until a
hiss is heard to prevent sprayed fuel from hurting
persons!
Danger: If the fuel is splashed on the vehicle body,
1. Hold the pull C1or C2 to support the cab with right
purge it using water immediately to prevent paint
hand while rotate the clip ring F to upper position
damage!
from the slot of clamp plate E with the other hand
and release the clamp plate E.
2. Hold the pull C1or C2 to lower the cab with right
hand until the safety hook D is hitched with the
hook housing J (Do not turn the handle A using
hand during operation. In addition, pay attention to
the cab and handle A during descending).
3. Press the handle A until it stops and is completely
locked with hook A.
3-56
 Structure description and operation(old cab)
Filler cap opening or locking Fuse box
The fuse box cover is attached with a tag that shows the
fuse model and is referred to for replacement of the
fuse.
Dismantle and installation of fuse:

Fuel tank
Close
locked
d

Opened
Key rotation angle Fuse box cover
Fuel tank unlocked Fuse box

1. Open the keyhole cap.

2. Insert the key, rotate it counter-clockwise for 90ºto
unlock the fuel tank cap, and then rotate the fuel
tank cap counter-clockwise to open.
3. Tighten the fuel tank cap clockwise, insert the key,
and rotate the key clockwise for 90ºto lock the fuel
tank cap. After locking, withdraw the key.
3-57
Structure description and operation(old cab)
The fuse box cover is clamped on the instrument panel
body and the skirts at both sides using the seven metal
clips. To repair the fuse box, directly pull out the cover.
To take the fuse box down, loosen the two screws
beneath the fuse box using the screwdriver, and then
directly pull out the fuse box.

Metal clip

Fuse box cover

3-58
 Structures descriptions and operations (B19 cab)

Structures descriptions and operations (B19 cab)

Arrangement of driver zone

1. Instrument 7. Tbox 13. Electric socket 19. Oil reservoir for

2. Card slot 8. Storage box 14. Ashtray clutch and brake
3. Air duct 9. Washing fluid reservoir 15. Small storage box 20. Reversing sensor
controller
4. Warning switch 10. Glove box 16. Cigarette lighter (mounted on the
5. Radio 11. Fuse case 17. Combination switch tubular beam)
6. Certificate box 12. Control panel of A/C and 18. Electric adjusting
heater switch of headlamp

4-1
Structures descriptions and operations (B19 cab)
Combination instrument

1. Engine tachometer 3. LCD 5. Page-turning button 7. Barometer

2. Fuel gauge 4. Speedometer of LCD 8. Steering indicator
6. Water temperature
gauge

4-2
 Structures descriptions and operations (B19 cab)

Instrument cluster LCD Display interface - (default Display interface II

interface)
screen

1. Instant fuel 3. Total fuel

consumption consumption
2. Average fuel
1. Adblue level 3. Total mileage consumption
2. Subtotal On the interface I, click the LCD
mileage page-turning button (for less than 2s),
changing the interface II shown in Fig.
By default, the LCD interface is shown in
1. LCD 2. Page-turning “HC0050G”.
the Figure “HC0040G”, including the
button The instantaneous fuel consumption is not
adblue level, mileage subtotal and total
mileage. On the interface I, press the LCD displayed until vehicle speed exceeds
page-turning button for more than 2s, 30km/h, with the max. display value not
zeroing the subtotal mileage. more than 20L/100km.

4-3
Structures descriptions and operations (B19 cab)
Displayed interface III Speedometer Barometer

Barometer

1. Prompt 3. Fault code
design
4. Sequence of
2. Quantity of fault codes
fault codes
When there is something wrong with the
engine, the interface III pops up by itself,
as shown in “HC0060G”. On the interface
III, you could turn the pages of fault codes
with the page-turning button of LCD:
press it rightwards to view the next fault
code and press it leftwards to view the
previous fault code. Click the LCD
page-turning button (for less than 2s),
returning to the interface I.
Click the LCD page-turning button (for
less than 2s), changing over the interfaces
I, II, and III in sequence. However, in case
of engine faults, interface III does not pop
up.
Water
temperature
gauge
1. LCD 2. Page-turning There are two barometers, respectively
button indicating the air pressure of air reservoir
of brake in front and rear axle. The range
The pointer of speedometer indicates the of barometer: 0~12×100kPa;
real-time vehicle speed, expressed in km/h. 0~4.5×100kPa scales are red, and when
The odometer indicate the total mileage any barometer indicates ≤450kPa, the
expressed in km. brake fault indicator lights up. If the
Caution: With vehicle running, it is pointer is within the red zone, it is
prohibited to turn the page-turning prohibited to drive away the vehicle.
button, which otherwise may damage to
the speedometer.
Caution: The page-turning button
cannot be pulled out or rotated.

4-4

Electronic tachometer
Tachometer
Fuel
gauge
Electronic tachometer of engine shows the
instantaneous RPM of engine, expressed
as 1000r/min. Mileage: 0~5000r/min; min.
scale value: 200r/min; 4×1000r/min and
above being of red zone. It is prohibited
that the engine RPM exceeds the critical
range in any case.
Structures descriptions and operations (B19 cab)
Water temperature gauge
Barometer
Water
temperature
gauge
Water temperature gauge
Coolant thermometer is used to show the
coolant temperature. Coolant temperature
is dependent on the ambient temperature
and running conditions. Coolant
thermometer range: C(40°C)~H(120°C)
Note: when the coolant gauge pointer
goes beyond the normal range, please
immediately check if its warning
indicator lights up; if so, please pull over
the vehicle to safety as soon as possible.
(Driving with the engine overheating
could severely damage it). If the
indicator does not light up, please keep
driving.
Fuel gauge
Tachometer
Fuel
gauge
Fuel gauge is used to show the level in fuel
tank, and its pointer may jump in braking,
cornering, acceleration or uphill/downhill
traveling. . Its range: E-1/2-F; oil-level
warning zone: 1/16 and below.
When the fuel gauge indicator lights up, it
is needed to refuel the vehicle.
4-5
Structures descriptions and operations (B19 cab)
Indicator and alarm lamp
High beam Parking brake Fuel-water Front fog lamp Low beam
indicator indicator lamp separator warning indicator lamp indicator lamp
lamp lamp

OBD warning Intake preheating Rear fog lamp Exhaust brake Coolant
lamp indicator lamp indicator lamp indicator lamp temperature
warning indicator

Charging Engine oil Engine Low water level Turn

indicator pressure warning malfunction warning lamp signal/warning
lamp lamp indicator lamp lamp

Fuel level Filament check Brake failure Cruise indicator Airbag indicator
warning lamp warning lamp indicator lamp

Position Seat belt warning ABS indicator Air filter Engine

indicator lamp lamp blockage malfunction
lamp warning lamp indicator lamp

Stop warning Maintenance Daytime driving Tire-pressure

indicator warning indicator light warning indicator

Warning Dimming DPF Driver warning

indicator of indicator re-generation indicator
brake shoe indicator
wearing

Door-unclosed Warning indicator

indicator of adblue level too
low

4-6

High beam indicator lamp
This indicator lamp turns on when the high
beam is turned on or the overtaking lamp
is operated.
Parking brake indicator lamp
When the parking brake handle is pulled
up, this indicator lamp turns on to alert the
driver that the parking brake of the vehicle
is applied. This indicator lamp turns off
when the parking brake handle is released.
Ensure that this indicator lamp is off
before starting up the vehicle.
Fuel-water separator warning
lamp
If this warning lamp turns on during the
running of engine, it reminds the driver of
draining the water from the fuel-water
separator.
OBD warning lamp
This indicator lamp turns on in event of
any emission malfunction of the engine.
Please observe the trouble code.
Intake preheating indicator lamp
This indicator lamp turns on when the key
is rotated to position ON. This indicator
Structures descriptions and operations (B19 cab)
lamp turns off when the engine is
preheated to a certain temperature, in
which case the engine can be started.
Exhaust brake indicator lamp
(Optional)
The exhaust brake indicator lamp turns on
when the exhaust brake system is working.
Water temperature warning indicator lamp
The warning lamp turns on when the water
temperature exceeds certain value.
Charging indicator lamp
This indicator lamp will turn on when the
key switch is at position “ON”. This lamp
will turn off after the engine is started so
that the alternator is charging the battery. If
the charging system is malfunctioned
during the driving of the vehicle, this lamp
will turn on.
Caution: Never continue to drive the
vehicle when this indicator lamp turns
on, otherwise the battery performance
will be deteriorated gradually and the
life will be shortened remarkably.
Engine oil pressure warning lamp
This lamp turns on when the key switch is
rotated to position ON and turns off after
the engine is started. In event of abnormal
drop of engine oil pressure during the
running of the engine, this lamp will turn
on for warning.
Caution: The under-low engine oil
pressure will lead to burnout of the
engine.
Caution: If this warning lamp turns on
due to low engine oil pressure, it’s
prohibited to continue the driving of the
vehicle.
Engine malfunction indicator
lamp
This indicator lamp turns on in event of
any malfunction of the engine. Please
observe the trouble code.
Low water level warning lamp
(Optional)
Turn signal/warning lamp
This indicator lamp flashes when the turn
signal lamp switch or hazard warning
switch is turned on.
Fuel level warning lamp
If the fuel volume in the fuel tank is few,
this warning lamp will turn on to remind
the driver of refueling, in order to
4-7
Structures descriptions and operations (B19 cab)
guarantee the normal driving of the
vehicle.
Filament check warning lamp
This warning lamp turns on in event of
malfunction in any rear lamp (except turn
signal lamp and reversing lamp) of the
vehicle.
Brake failure indicator
If this warning lamp turns on during
running of engine, check the volume of
brake fluid. If the fluid level in the
reservoir is below the marking MIN,
please add the brake fluid.
The brake warning lamp turns on in event
of low vacuum pressure of the vacuum
booster.
Caution: The braking distance will be
increased when the brake pedal is
depressed with engine stopped or low
brake fluid level. Therefore, a higher
depressing force is required.
Cruise control indicator lamp
(Optional)
Airbag indicator lamp (Optional)
Position indicator lamp
This indicator lamp turns on when the
4-8
position lamp is turned on.
Seat belt warning lamp
This warning lamp reminds the driver of
fastening the seat belt. This warning lamp
turns on when the ignition switch is rotated
to position ON and turns off after the
driver fastens the seat belt.
ABS indicator lamp (optional)
When the ignition switch is rotated to
position ON, the ABS indicator lamp turns
on and then off, which indicates that the
ABS functions normally.
If the ABS indicator lamp turns on during
the running of engine or during driving of
vehicle, it indicates the abnormal
functioning of the ABS system. Please
contact an authorized service station for
checking.
In event of malfunction of ABS system,
the anti-lock brake function fails. The
brake system is still working under
conventional mode.
Air filter blockage warning lamp
(Optional)
Engine malfunction indicator
lamp
Warning indicator of engine faults: please
go to the nearby service station for
inspection as soon as possible when this
indicator goes on.
Stop warning indicator
This shows the occurrence of serious or
fatal fault and that the vehicle must be
stopped.
Maintenance warning indicator
This lamp will be lit in the case of fault. At
this time, the vehicle must be sent to repair
station for inspection as possible.
Caution: As for the warning indicators
of engine shutdown, engine faults and
engine maintenance, when one or more
indicator lights up, the mileage/fault
screen also display the fault code and
please follow the prompts in operations.
Daytime driving light
When the engine is started, the daytime
running lamp will light up automatically,
so as to attract the attentions of other
vehicles, non-motor vehicles and
pedestrians. If the low beam is turned on
manually at night, the daytime running
lamp will go out by itself.

Tire-pressure warning indicator
(optional)
This indicator lights up if the tire equipped
with tire-pressure monitor sensor is at the
increased or decreased pressure or if the
tire-pressure monitor system fails, so as to
alert the driver of safety inspection.
Warning indicator of brake shoe
wearing
In order to guarantee the brake
performance and traveling safety, this
indicator will light up to alert driver of the
brake shoe replacement or repaired if the
brake shoe wears to the service limit.
Dimming indicator
Structures descriptions and operations (B19 cab)
1. Default interface 2. Knob
With the combine instrument at the small
lamp mode, by default, rotate the knob
upwards or downwards to adjust the
background brightness at night mode.
DPF re-generation indicator
DPF regeneration indicator is used to
indicate if the DPF needs to be
re-generated, with the conditions of
indicator lighting up:
When DPF load increases to a certain
value, the indicator lights up, prompting
the driver of the DPF needing to be
regenerated.
When DPF load increases closely to the
critical level, the indicator begin to flash
continuously at 1Hz of frequency.
When the DPF load reaches the critical
level, the engine warning indicator lights
up and the DPF indicator flashes always.
If the DPF load beyond the critical level is
ignored, DPF indicator goes out and the
red stop indicator lights up, which means
the engine will be shut down immediately
and the DPF cannot be regenerated. .
This particulate filter indicator also
indicates that DPF regeneration is
performed with the compulsory
regeneration switch.
Driver warning indicator
This indicator lights up if it is detected that
the adblue level is low or deteriorated or
the exhaust system is falsified or NOX
exceeds the standard, and meanwhile the
torque and vehicle speed decrease.
Door-unclosed indicator
This indicator lights up, meaning one door
at least is not closed up.
If the door is closed a little, not fully and
completely, the indicator may go out, but
please lock up your doors.
This indicator could work even though the
ignition switch is OFF.
Warning indicator of adblue level
too low
This indicator is used to show the LCD
status. If it lights up, the 1st line on LCD
shows the percentage of adblue level. At
this time, press the reset, changing to
subtotal mileage on the 1st line and this
indicator goes out.
4-9
Structures descriptions and operations (B19 cab)
Manually turn the lock button on the
Vehicle key 1. Indicator lamp 2. Lock
driver’s side anti-clockwise to unlock all
3. Unlock doors. The steering light does not flash.
Remote unlocking Manually turn the lock button on the
driver’s side clockwise to lock all doors.
Turn ignition lock to OFF, close all doors
The steering light does not flash.；
and press remote unlock button;
Remote locking Others
Turn ignition lock to OFF, close all doors The remote control does not work when
and press remote lock button; the ignition lock is turned to ACC or IGN.

Finding of vehicle Ignition switch

All doors are locked and press lock button;
Reminding of door unclosed
Turn the ignition lock to OFF, any door is Lock
open, press remote lock button; however
the doors are not locked;
Turn the ignition lock to OFF, any door is
open, press remote unlock button and all
doors are unlocked;
Manual locking and unlocking
Manual pull the door lock button on the
driver’s side to unlock all doors. The LOCK (key): the key shall be inserted to
steering light does not flash. the switch when it is turned to LOCK only.
Manual push the door lock button on the PUSH: when turning the key from ACC to
driver’s side to lock all doors. The steering LOCK, first turn the key from ACC to
light does not flash. PUSH, second, press the key at PUSH,

4-10

finally, turn the key to LOCK.
ACC (accessories): in order to use the
accessories (such as the radio-player,
wiper and cigar lighter) with the engine
not running, you could turn the key to this
gear.
ON (connected): after the engine is started,
the key will return to ON from START and
the engine will operate normally. When the
engine is in operation, never turn the key
to other positions.
R or H preheating (if equipped): turn the
key to pre-heating gear in case of starting
the engine in cold winter. Preheating time
depends on the driver.
START: Turn the key to START to run the
starter and start the engine. Release the
key at START and the key returns to ON.
Note: Never turn the key to START
when the engine is working; otherwise
the starter may be damaged. Never start
the engine unless it has stopped.
Note: when turning the key from ACC
to LOCK, press the key at PUSH,
instead of turning to LOCK directly;
otherwise the key may be damaged.
Structures descriptions and operations (B19 cab)
Combination switch
Wiper and washer switch
The wiper and washer are operational
when the ignition switch is at position
ACC or ON.
Shift the lever to wipe:
1. Position OFF: Initial position
2. Position MIST: Pull upward the
control lever to operate the wiper
once. After the wiping, the control
lever automatically returns upon
release.
3. Position INT: Pull downward the
control lever once to run the wiper
motor at intermediate mode, with the
intermittent interval at 4~6s.
4. Position LO: Pull downward the
control lever twice continuously to
run the wiper motor at low speed.
5. Position HI: Pull downward the
control lever thrice continuously to
run the wiper motor at high speed.
6. Rotate the control lever along
direction “A” shown in the figure to
start the washer. After the operation,
the control lever will return
automatically upon release.
Caution: Do not run the washer
continuously for more than 30s.
Caution: Do not use when the washing
fluid reservoir is empty or frozen.
Caution: Under cold weathers, generally
remove the ice from the windscreen
before operating the wiper.
Danger: When the air temperature is
below 0ºC, the washing fluid will be
frozen probably on the windscreen to
obstruct the visual field. Before
operating the windscreen washer, please
turn on the heater control switch to heat
up the windscreen.
4-11
Structures descriptions and operations (B19 cab)
Exhaust brake switch
Rotate the lever 1 to position “ON”. The
exhaust brake indicator lamp turns on. In
such case, if both accelerator pedal and
clutch pedal are released (provided the
gearshift lever is at a drive gear), the
exhaust brake is functioning. The exhaust
brake is automatically deactivated when
the accelerator pedal or clutch pedal is
depressed. In such case, the exhaust brake
will continue to run when the accelerator
pedal or clutch pedal is released again.
Rotate the lever 1 to position “OFF”. In
such case, the exhaust brake stops working
and the exhaust brake indicator lamp turns
off.
Caution: Please use the exhaust brake
while the vehicle is driving down a long
slope. Ensure to turn on the exhaust
4-12
brake switch before driving down the
slope.
Lamplight switch
Caution: Do not turn on various lamps for
a long time with the engine stopped.
Rotate the control lever 1 to turn of the
following lamps in turn:
1. Position lamp: Front position lamp,
rear position lamp, clearance lamp,
marker lamp, license plate lamp, and
instrument lamp will turn on.
2. Low beam: Both the low beam and
the low beam indicator lamp will turn
on.
3. High beam: Rotate the lever 1 to
position “Low beam” and operate the
lever 1 along direction B to turn on
high beam and high beam indicator
lamp.
4. Dimmer switch and overtaking lamp:
When the lever 1 is at position “High
beam”, operate the lever 1 along the
directions A-B back and forth to
switch between low beam and high
beam. Operate the lever 1 along
direction A to turn on the overtaking
lamp (high beam) and release it to
allow automatic return of lever and
turn off high beam.

Turn signal lamp switch
Turn signal lamp
Pull up the lever along arrow direction to
turn on right turn signal lamp and pull
down the lever along arrow direction to
turn on left turn signal lamp.
The control lever will return automatically
at completion of cornering.
Structures descriptions and operations (B19 cab)
Rear fog lamp switch
Fog lamp switch
Front fog lamp switch
To turn on rear fog lamp:
After the front fog lamp is turned on,
Rotate the slide ring 1 along direction A to
rotate the slide ring to position “Rear fog
position “Front fog lamp” to turn on both
lamp” to turn on rear fog lamp. In such
front fog lamp and front fog lamp indicator
case, the position lamp is turned on
lamp. Use this switch while driving in
automatically. The rear fog lamp indicator
thick foggy weathers.
lamp turns on.
To turn off front fog lap, rotate the slide
To turn off rear fog lamp:
ring to position OFF.
1. Rotate the slide ring 1 to position
“Front fog lamp” to turn off the rear
fog lamp.
Caution: The position lamp remains on
after the turn-off of the rear fog lamp.
To turn off the position lamp, rotate the
lever 2 to position OFF.
4-13
Structures descriptions and operations (B19 cab)
2. Both rear fog lamp and rear fog lamp
indicator lamp turn off.
Caution: When the lighting switch is
rotated from the position “Position
lamp” to OFF, both position lamp and
rear fog lamp will be turned off
automatically.
Multi-functional steering
wheel
4-14
Multi-media volume increasing/decreasing the volume; release
the button, stopping the adjustment.
adjustment
Short press mute key 5 to mute the
multimedia.
Multimedia channel/music change
Click  with the handle in the front,
selecting the next song at MP3 mode or
the next channel at radio mode.
Press  with the handle in the front and
hold it, increasing the frequency
continuously at the radio mode; release it,
stopping at the current frequency.
Click  with the handle at the rear,
selecting the previous song at MP3 mode
1. Adjustment of multi-media volume and the previous channel at the radio
mode.
2. Multi-media channel / track
adjustment Press ▽ with the handle at the rear and
hold it, decreasing the frequency
3. Answer key of bluetooth phone continuously at the radio mode; release it,
4. Changeover of multi-media sound stopping at the current frequency.
source modes
Changeover of multi-media sound
5. Hang-up/mute button of bluetooth source mode
phone
Click SRC with the handle down,
Volume adjustment of multimedia switching the multimedia between
Click +/- once, increasing/decreasing the MP3/radio/AUX-IN modes.
volume by one gear. Bluetooth call
Press +/- and hold it, continuously

In case of incoming call, click the
bluetooth phone to answer it.
Click it to hang up the phone at the phone
call mode and to mute the phone at the
multimedia mode.
Cruise control - status I
Conditions to enter the cruise
1. In normal driving, vehicle speed
should be in the calibrated range
(Yuchai: 35km/h or above;
ZD30/ZD28: 40km/h or above;
Chaochai: 30km/h or above);
2. Above the set speed gear (III speed
Structures descriptions and operations (B19 cab)
gear); at -1.2km/s² of deceleration; release this
3. Engine rpm is between the proper button, vehicle speed showing up on the
range; instrument and vehicle running at the set
cruise. Besides, switch cannot be pressed
4. The brake and clutch switch signals for 20s or longer, otherwise, the cruise
are free from failure. function is activated
5. No failure of cruise control switch
Cruise recovery
Cruise activated Depress brake pedal or clutch pedal to quit
Click the button 2 with the handle in the cruise and then short press button 3 to
front, activating the cruise function, the recover and drive at last set speed.
cruise indicator on instrument lights up.
Cruise off
Cruise acceleration Click the button 4, deactivating the cruise
After the cruise function is activated, click function and the instrument indicator
the button 2, increasing the vehicle speed going out.
by 2km/h each time; press and hold it,
How to quit cruise
continuously increasing the vehicle speed
at the 1.5km/s²of acceleration; release the 1. Depress the brake;
button, vehicle speed showing up on the 2. Press cruise stop button;
instrument and vehicle running at the set
3. Depress the clutch;
cruise. Besides, switch cannot be pressed
for 20s or longer, otherwise, the cruise 4. Vehicle speed sensor fails or the
function is deactivated vehicle speed exceeds the calibrated
range (ZD30/ZD28: vehicle speed
Cruise deceleration ≥120km/h or ≤30km/h);
After the cruise function is activated, click 5. Engine RPM exceeds the proper
the button 1, decreasing the vehicle speed calibration range (ZD30/ZD28:
by 2km/h each time; press and hold it, engine RPM ≤1000rpm or
continuously decreasing the vehicle speed ≥4000km/h);
4-15
Structures descriptions and operations (B19 cab)
6. Activate the exhaust brake; Cruise activated
Cruise control - status II
Conditions to enter the cruise
1. For regular driving, the speed is
calibrated to proper range (Cummins
engine: above 48km/h);
2. Above the set speed gear (III speed
gear);
3. Engine rpm is between the proper
range;
4. The brake and clutch switch signals
are free from failure.
5. No failure of cruise control switch
4-16
How to quit cruise
Adjust the vehicle speed to operation 1. Depress the brake;
range, short press button 3 to activate the 2. Press cruise stop button;
cruise and the indicator goes on.
3. Depress the clutch;
Cruise speeding 4. Vehicle speed sensor fails or the
Shift the rod forward for twice and the speed is above the calibrated range;
vehicle speed increases or shift the rod 5. Engine rpm is out of specified range.
backward for once to decrease the vehicle
speed. Long press the button to 6. Activate the exhaust brake;
continuously increase or decrease the
speed and release the button to set the PTO function - status I
speed.
Setting of cruising speed
When the cruise is in standby mode, shift
the rod backward for once to start cruise at
current speed.
Cruise recovery
Depress brake pedal or clutch pedal to quit
cruise and then short press button 2 to
recover and drive at last set speed.
Cruise off
Short press button 3 to turn off cruise and
the cruise indicator goes off.
Conditions to use PTO
1. Vehicle speed should be in the
calibrated range (Yuchai: : 35km/h or

above; ZD30/ZD28: 40km/h or above; Condition to exit PTO
Chaochai: 30km/h or above);
1.
2. Engine RPM is in the calibrated range
2.
(less than the calibrated value).
3.
3. Brake pedal is not depressed down.
4. Cruise control switches don’t have
any faults.
4.
PTO activated 5.
When PTO service conditions are met,
PTO function - status II
click the button 3, activating the PTO
functions, and the engine RPM increases
to the initial value.
PTO acceleration
After PTO functions is activated, click the
button 2, increasing the engine RPM by
the set value each time; press and hold it,
continuously increasing the engine RPM.
PTO deceleration
After PTO functions is activated, click the
button 1, decreasing the engine RPM by
the set value each time; press and hold it,
continuously decreasing the engine RPM.
Conditions to use PTO
PTO deactivated
1.
Click the button 4, exiting the PTO
function.
Structures descriptions and operations (B19 cab)
Depress the brake;
Press cruise stop button;
Vehicle speed exceeds the calibrated
range (ZD30/ZD28: vehicle speed
≥120km/h or ≤30km/h);
Engine rpm is out of specified range.
Activate the exhaust brake;
Vehicle speed is in the calibrated
range (Cummins engine: 48km/h or
above)
2. Engine RPM is in the calibrated range
(less than the calibrated value).
3. Brake pedal is not depressed down.
4. Cruise control switches don’t have
any faults.
PTO activated:
Click the button 3, activating the PTO.
PTO speed regulation
Click the button 2, engine running at
1000rpm (calibratable); click the button 1,
engine running at 2000rpm (calibratable).
PTO speed regulation
Press the button 1 or 2, increasing or
decreasing the engine RPM at the constant
rate; release it, setting the RPM: 48km/h.
PTO deactivated
Click the button 3, quitting the PTO.
Condition to exit PTO
1. Depress the brake;
2. Press cruise stop button;
3. Vehicle speed exceeds the calibrated
range.
4. Engine rpm is out of specified range.
4-17
Structures descriptions and operations (B19 cab)
5. Activate the exhaust brake;
Headlamp dimmer switch
Under different loads, the driver cab will
change horizontally to result in the change
of irradiation position of headlamp light.
Therefore, the low beam of headlamp
needs to be adjusted to ensure the correct
irradiation position.
Position 0: adjust up the headlamp light
beam.
Position -: normal, no adjustment is
needed.
Position 1, 2 and 3: adjust down the
headlamp light beam.
Daytime driving light
When the engine rpm is above 400rpm, the
4-18
daytime driving light is illuminated. service station (active regeneration
When the position light is illuminated, the in situ with diagnostic apparatus
daytime driving light is off. and regeneration in situ with
regenerator switch)
Re-generation switch (if
1. Vehicle idles on site, with engine
equipped) RPM less than 3000rpm.
2. Transmission is at neutral gear and
tension up the handle brake.
3. Don’t depress the clutch;
4. Don’t depress the accelerator pedal;
Re-generation
switch 5. Don’t depress the brake pedal;
6. Engine coolant temperature higher
than 50℃;
7. Fuel temperature below 105℃;
8. Carbon particle value is higher than 0
and less than 45g.
Conditions to trigger the
Caution: Conditions to release the
regeneration regenerator in situ by using the
diagnostic instrument: carbon particle
Conditions to release the DPF auto
regeneration value is between 0 and 45g; conditions
to release the regeneration in situ by
1. Vehicle runs normally (exhaust using the regenerator switch: carbon
temperature reaches a certain value), particle value is between 30g and 45g.
2. The carbon particle value is more
than 30g. Illustration of system status
Active regeneration in situ at When the vehicle does not yet reach the

regeneration requirements (for more, see
the conditions to trigger regeneration), the
regenerator indicator does not light up, nor
the SVS fault indicator, nor the OBD (MIL)
indicator. Moreover, it is useless to press
the regenerator switch on instrument panel
when the vehicle don’t reach the
regeneration requirements.
If the regenerator indicator alone on
instrument lights up, it means the vehicle
is under the automatic regeneration status
(carbon load: 30-32g). At this time, the
vehicle could run normally and the output
torque of engine is unlimited. If the idling
lasts for a certain time during the
regeneration, the automatic regeneration
will stop and the regenerator indicator on
instrument will goes out; however, when
the regeneration-triggering conditions are
met, the automatic regeneration will be
performed again and the indicator lights up
until the regeneration ends (carbon load
less than 30g).
It is useless to press the regenerator switch
on instrument during the automatic
regeneration.
When the SVS fault indicator lights up, it
means the carbon particles are slightly
overloaded, with carbon load at 32-36g. At
Structures descriptions and operations (B19 cab)
this time, the vehicle could run normally
and the output torque of engine is not
limited, but the light overloading fault of
carbon particles will pop up, with P2463
of fault code and prompting driver of
diagnosis and maintenance at service
station.
There are two kinds of regeneration modes
at service station:
If the vehicle runs normally, system could
perform the automatic regeneration and the
regenerator indicator lights up until the
regeneration ends (carbon load less than
30g), and after the regeneration, the SVS
fault indicator also goes out.
If vehicle cannot run, the diagnostic
apparatus or regenerator switch could be
used to perform the active regeneration in
situ: press the regenerator switch on
instrument, performing the regeneration
and the regenerator indicator lighting up.
After the regeneration (carbon load less
than 30g), the indicator and SVS fault
indicator go out. . If the regenerator switch
is pressed during the regeneration, the
regeneration will be immediately
suspended and its indicator goes out, but,
if vehicle is still in the overloading status
of carbon particles (carbon load more than
32g), the SVS fault indicator is still ON.
Besides, if the on-site regeneration
conditions are met after the compulsory
breaking, the system will perform the
regeneration again.
When the SVS fault indicator and OBD
(MIL) indicator lights up, it means the
carbon particles are moderately overloaded
(carbon load: 36g-45g) or clogged (carbon
load more than 45g). In such case, vehicle
could run, but the output torque of engine
is limited partially, with the fault code
P2463 (slight overloading) popping out,
prompting driver of diagnosis and
maintenance at service station.
If the automatic regeneration functions are
prohibited, it is needed to perform the
active regeneration with the diagnostic
apparatus or regenerator switch, or replace
with a new DPF if needed.
• If Pressing the regenerator switch on
instrument panel enables the system
to perform the regeneration and the
regenerator indicator to light up, it
means the carbon particles is
moderately overloaded (carbon load
36g-45g). After the regeneration
(carbon load less than 30g), both the
regenerator indicator, SVS fault
4-19
Structures descriptions and operations (B19 cab)
indicator and OBD (MIL) indicator 550℃~580℃) and concentration of some ECU data is read through the OBD port
go out. If the regenerator switch is harmful gases may also rise. Therefore, it located at the left side of driver, as shown
pressed during the regeneration, the is needed to pay attention to the following: in the figure. .
regeneration will be immediately 1. Vehicle should be kept away from the Connect the diagnostic apparatus to the
suspended and its indicator goes out, flammables, especially the exhaust ECU port, so as to read the VIN.
but, if vehicle is still in the pipe, so as to avoid the accidents!
overloading status of carbon particles, The diagnostic apparatus, as long as
the SVS fault indicator and OBD 2. No persons is allowed to be close to meeting the engine communication
(MIL) are still ON. When the exhaust pipe or directly touch the protocol, could read the vehicle
regenerator switch is pressed again exhaust pipe. information. Moreover, in case of
after the compulsory termination, the 3. Don’t perform the DPF regeneration abnormality, please contact with the
system will continue the regeneration in the closed areas. authorized service station of Dongfeng
if the on-site active regeneration Automobile Co., Ltd.
conditions are met. OBD port
• If the system does not perform the
regeneration and the regenerator
indicator does not light up after
regenerator switch on instrument
panel is pressed, it means the carbon
particles are clogged (carbon load
more than 45g), which needs to be
handled immediately at the nearby
service station.
Precautions
There are a lot of heat generated during the
in-situ active regeneration at the service
station (through the regenerator switch and
diagnostic apparatus) (the air temperature
around the exhaust pipe could reach

4-20
 Structures descriptions and operations (B19 cab)

Central control panel

Configuration I Configuration II Configuration III

1. Vent 5. A/C
2. Radio+MP3+traveling data recorder 6. Cigar lighter
3. 10” LCD 7. Ash tray
4. Radio+MP3 8. Charger socket

4-21
Structures descriptions and operations (B19 cab)
1. Blowing mode knob
A/C system
— Head blowing
Vent
—Foot blowing

— Head and foot blowing

— Internal warming and window defrosting

— Window defrosting
2. Fan gear knob
Turn button Fan switch has five gears: 0, 1, 2, 3 and 4. At gear 0: fan is OFF;
from gears 1 to 4, the fan speed increases one by one.
The block is available to adjust the air flow direction. 3. Warming/cooling mode knob
For cooling down, turn the knob to the blue marker; for heating,
A/C turn the knob to the red marker.
4. A/C Switch
To turn on this A/C, press this button and turn the cooling/warming
mode knob to the blue marker.
5. Internal/external circulation button
With knob at the normal state — naturally ventilation (external
1. Blowing mode 4. A/C button fresh air comes in)
knob 5. Internal/
2. Fan gear knob external With knob pressed down — internal circulation
3. Warming/ circulation
cooling mode button
knob

4-22
 Structures descriptions and operations (B19 cab)
Radio

1. Left knob 6. Phone hanging up 10. “Button 4” RDM 14. USB port
2. Microphone /BAND 11. “Button 3” PRT 15. MODE/CLK
3. LCD 7. EQ 12. “Button 2”
4. Phone answering 8. “Button 6” 13. “Button 1”
/APS downwards
5. Right knob 9. “Button 5” upwards

4-23
Structures descriptions and operations (B19 cab)
As for the following illustration, click
duration ＜3s and pressing ＞3s
1. Left knob
Under the standby state: click it for
power off
Adjustment interface of radio and its
frequency: ① click it to mute and
re-click it to resume; ② press it for
power off; ③ rotate it leftwards to
turn down the volume and rotate
rightwards to turn up the volume.
On MP3 interface: ① click it to mute
and re-click it to resume; ② press it
for power off; ③ rotate it leftwards
to turn down the volume and rotate
rightwards to turn up the volume.
Bluetooth music: ① click it to mute
and re-click it to resume; ② press it
for power off ③ rotate it leftwards to
turn down the volume and rotate
rightwards to turn up the volume.
Clock setting interface: ① click it to
mute and re-click it to resume; ②
press it to power off
Sound effect setting: press it for power
off
4-24
Incoming call: click it to mute the
speaker and re-click it to resume the
call.
Bluetooth call: ① click it to mute the
microphone and re-click it to resume;
②press it for power off; ③ rotate it
leftwards to turn down the volume and
rotate rightwards to turn up the
volume.
2. Microphone
3. “LCD”
Under the standby state: Display the
time;
Other status: display the functions.
4. “Phone answering /APS”
Under the standby state: Answering
when a phone comes in.
Adjustment interface of radio and its
frequency: ① click it to call the last
phone; ② press it to automatically
scan and store the channels into the
1-6 addresses of FM1/FM2/FM3
bands, totaling 18 channels. After the
channel searching, No. 1 station of
FM1 band plays by default.
On MP3 interface: Click it to dial
the last call number;
Bluetooth music: click it to call the
last phone call.
Incoming call: Click it to answer the
phone.
5. Right knob
Adjustment interface of radio and its
frequency: turn it rightwards to
decrease the frequency by 0.1MHZ
and turn it leftwards to increase the
frequency 0.1MHZ. After that, the
frequency state is not saved.
On MP3 interface: Press it to enter
the radio setting menu;
Bluetooth music: Press it to enter the
radio setting menu;
Clock setting interface: Turn it
leftwards to adjust the hour and turn it
rightwards to adjust the minute.
Sound effect setting: ① click it to
sequentially change between BAS
(bass)/TRE (treble) /BAL (left and
right offsets); at the BAS and TRE,
turn it leftwards for adjustment from 0
to 7 and turn it rightwards from 0 to
+7; at BAL status, turn it leftwards to
the left sound channel and turn it
rightwards to the right sound channel;
② press it to save the current setting

and then exit it.
6. “Phone hanging-up /BAND”
Under the standby state: Phone
hanging-up
9.
Adjustment interface of radio and its
frequency: click it to change between
FM1 and FM2 and FM3 in order.
Incoming call: Phone hanging-up
In bluetooth phone-calling: hang up
the phone
7. “EQ”
Adjustment interface of radio and its
frequency: click it to cycle the sound
10. “Button 4” / RDM
effect: CLASS, POP, ROCK, VOCAL,
JAZZ.
On MP3 interface: Click it cycle the
sound effect: CLASS, POP, ROCK,
VOCAL, JAZZ.
Bluetooth music: Click it cycle the
sound effect: CLASS, POP, ROCK,
VOCAL, JAZZ.
8. “Button 6” downwards
Adjustment interface of radio and its
11. “Button 3” / PRT
frequency:① click it to change to No.
6 preset channel frequency at the
current band; ② press it to store the
Structures descriptions and operations (B19 cab)
current frequency into the No. 6
station of current band.
On MP3 interface: Select the next
song.
“Button 5” upwards
Adjustment interface of radio and its
frequency:① click it to change to No.
5 preset channel frequency at the
current band; ② press it to store the
current frequency into the No. 5
station of current band.
On MP3 interface: Select the current
song.
Adjustment interface of radio and its
frequency:① click it to change to No.
4 preset channel frequency at the
current band; ② press it to store the
current frequency into the No. 4
station of current band.
On MP3 interface: Press it for the
random play and re-press it for
circular play.
Adjustment interface of radio and its
frequency: ① click it to change to
No. 3 preset channel frequency at the
current band; ② press it to store the
current frequency into the No. 3
station of current band.
On MP3 interface: Press it to
repeatedly play the current song and
re-press it to resume the circular play.
12. “Button 2”
Adjustment interface of radio and its
frequency:① click it to change to No.
2 preset channel frequency at the
current band; ② press it to store the
current frequency into the No. 2
station of current band.
Structures descriptions and operations
(2020-Version B19 cab)
13. “Button 1”
Adjustment interface of radio and its
frequency:① click it to change to No.
1 preset channel frequency at the
current band; ② press it to store the
current frequency into the No. 1
station of current band.
14. “USB port”
Charge your cellphones or play the
music in USB flash disk.
4-25
Structures descriptions and operations (B19 cab)
15. “MODE/CLK” As for how to use MP5, refer to its electronic instruction in the way
Adjustment interface of radio and its frequency, MP3 interface of Start - Homepage - Vehicle - Use Instruction
and bluetooth music: ① click it to change over the modes Caution: It is used for the 9V-32V battery with negative grounding.
(radio /MP3/bluetooth music); ② press it to display the clock, Caution: It cannot be mounted at a part hindering the driver’s field
which quits out automatically in 5s; re-press it to display the of view or affecting the driver’s operation.
clock and re-click it to quit the setting interface.
Caution: Intelligent on-board terminals are composed of
Clock setting interface: Click it to quit the setting interface. complicated parts and thus cannot be adjusted or uncovered. For its
repair, please consult the nearby professional service station.
Intelligent on-board terminals Caution: In case of the following phenomenon, immediately stop to
Intelligent MP5 send it to after-sale service center for repair: no sound, no image,
water or small objects enters into this terminal, smoke or odor;
otherwise, it may catch fire or result in other accidents. .
Caution: Don’t use any hard object to touch the LCD, in case it
may be scratched.
Danger: in order to avoid any accidents arising from the driver
distracting, driver cannot use this terminal or watch the screen in
while driving, and park vehicle at safety site firstly if needed
indeed
1. MIC microphone Danger: this terminal, on-board amplifier and speaker cannot be
exposed to the excessively humid environment or wetted, which
2. Volume knob otherwise may cause the short circuit, fire or other damages.
3. Switch (click it to mute / press it to enter the standby) Danger: don’t replace the fuse of attached power supply connector,
4. Homepage (return to homepage) as any unmatched fuse cannot protect the terminal current or even
5. Return (return to the upper level) may burn it, leading to a fire.
6. MODE (sound effect changeover)
7. Media equipment port

4-26

Cigarette lighter
To use the cigar lighter, directly press it to the end, release it; after
10s, the resistance wire in the front of cigar lighter gets hot and
automatically pop out to the original position, meaning it is ok to
light up your cigarette. After using, put it back.
Structures descriptions and operations (B19 cab)
Note: when the cigar lighter cannot pop out in 10s after you release
it, please pull it out manually to avoid other possible accidents.
Care must be taken to use the cigar lighter, as misuse of it may
cause fire.
Caution: Do not keep the cigar lighter pressed for a long time.
Caution: Please use the genuine Dongfeng cigar lighter and do not
change it at will; otherwise we will take no responsibility for fire
caused by cigar lighter.
Ashtray
Pull it backward out to use the ashtray. To clean it, while pulling it
backward, press the reed at the rear end to take it down.
Caution: Before leaving vehicle, close the ashtray for safety.
4-27
Structures descriptions and operations (B19 cab)
Roof lamp Lever, steering wheel and Parking brake handle
accessories
Transmission control lever

O position
When the vehicle door is opened, the roof
lamp will be lit. When the vehicle door is
closed, this lamp will be off.
OFF position
The roof lamp is not lit whether the
vehicle door is at any position.
ON position
The roof lamp maintains lit whether the
vehicle door is at any position.
Before shifting gear, the clutch pedal must
be stepped thoroughly. Before the forward
gear is changed to reverse gear or vice visa,
the vehicle must be parked completely.
When the shifting lever is moved to "R"
(reverse gear), the reversing lamp will be
lit and the reversing buzzer will give an
alarm to remind other vehicles and road
users.
For the gear distribution of different
vehicle, refer to specific vehicle model.
1. Forwards release
2. Backwards brake
3. Pull-up
After vehicle standing still, pull the
manual brake handle backwards to the
lock position; to release the parking brake,
pull the lock bushing upwards and move
the manual brake handle forwards (if the
air pressure is low, the parking brake
cannot be released.)
Caution: Please try to park your vehicle
at flat place.

4-28
 Structures descriptions and operations (B19 cab)
Adjustment of steering wheel stopping.
Rearview mirror
Wide-angle mirror: reduce the blind-zone
scope and widen the field of view, so as
for user to better see the rear road
conditions.
Close-proximity rearview mirror: it can
Adjustment
give the visual field around the right body
of driver cab.
Danger: do not change the rearview
Pull-up mirror’ angle while vehicle is running,
which otherwise is prone to cause traffic
accident.
With the lock lever released, the steering
wheel could incline forward or backward Rear side window
by up to 15° and upward or downward 1. Internal rearview mirror
move by the max. travel of 30mm. Before 2. Left outer rearview mirror
the adjusting of the steering wheel, the 3. Left wide-angle mirror
driver’ s seat has to be adjusted properly.
After the adjustment, lock the steering 4. Front-lower view mirror
wheel to prevent its displacement in 5. Right outer rearview mirror
running.
6. Right wide-angle mirror
Danger: the adjustment of steering wheel
7. Close-proximity mirror
is done while the vehicle stands still. It is
prohibited to adjust the steering wheel The main rearview mirror can give the
during Car traveling. visual field far behind the vehicle but the
visual field is narrow.
Front-lower view mirror: view the
dead-front field of view in startup and The diver cab with sleeper is equipped
4-29
Structures descriptions and operations (B19 cab)
with left and right rear windows which can
be opened for ventilation.
Electric window
Driver’s side
Front Rear
1. Lifter lock button of power window
2. Front passenger window lifter button
3. Lifter button of driver’s window
Lifting of power window
Press the front part of lifter button to raise
the glass, and release the button, stopping
the glass.
Press the rear part of lifter button for
longer than 300ms to lower the glass, and
release it, stopping the glass.
Short press the rear of power glass button
for no longer than 300ms and the glass
descends automatically (only the driver’s
side). When the glass is descending, press
the button to stop the glass.
Note: press the button to rise or drop
4-30
the glass. If the glass has moved to the
limit, never press the button ; otherwise
the motor may be damaged.
Micro-wave window
Micro-wave window
First press the door button as per the right
Front windscreen arrow in drawing and pull outwards the
handle as per the left arrow to open the
door.
Up to now, the micro-wave window of cab Door inside
is at middle-upper part of front windshield,
Internal handle
with the dimensions shown below.
Door
Door opening/closing
Door outside
Pull the internal handle as per the arrow in
drawing to open the door.
Danger: After the closing of doors, please
 Structures descriptions and operations (B19 cab)
check once again to ensure that the doors Backrest adjustment of
are closed tightly. Driving with doors
Seat adjustment
half-closed is really dangerous. driver’s seat
Forward or backward
Locking of doors adjustment of driver’s seat
From the outside of vehicle:
Backrest angle
handle

Release
While lifting the handle at the left side of
Lock Rail handle seat, move the backrest the comfortable
Push the slider handle at front-lower side position of holding the steering wheel;
Rotate the key counterclockwise, locking
of seat along the arrow, so as to move the then release the handle to have the
up the door and rotate it clockwise,
seat backward and forward until the pedal backrest locked at the needed angle.
opening the door.
is depressed to the best position; then Adjust the slider handle forwards or
release the handle to have the seat locked backwards to move the seat forwards or
at the needed position. backwards.
Danger: Do not adjust the driver seat
longitudinally during the driving of the
vehicle.

4-31
Structures descriptions and operations (B19 cab)
Adjustment of co-driver’s adjust the seatbelt until you feel
Seatbelt comfortable.
backrest
The middle seat seatbelt is of two-point
type: to use it, pass the webbing from your
Three-point hip area and insert the tongue into the
buckle. Then, adjust the seatbelt until you
feel comfortable.
2. Release of seat belt
Insert and
tighten it To release the seatbelt, just press down the
Press the button on buckle, and it automatically
buckle retracts back.
Caution: Ensure seatbelt is not twined
or does not rub against the edge of hard
objects; besides, care must be taken to
1. Adjustment lever of middle backrest prevent the chemicals and battery
angle electrolyte from being polluted.
2. Adjustment lever of co-driver’s Caution: One seatbelt is only for one
backrest angle person.
The adjustment lever of co-driver’s Caution: After the heavily impacting or
backrest angle could be used to lay down with any part invalid or damaged, the
the backrest. entire seatbelt should be replaced.
The adjustment lever of middle backrest Driver, passenger and middle seats are Caution: If stuck, the retractor should
angle could be used to lay down the equipped with the seatbelt. be replaced immediately.
middle backrest. 1. Seatbelt buckling
To use the three-point seatbelt, slowly pull
the webbing from the retractor, pass it
from your shoulder, neck and check, and
insert the tongue into the buckle. Then,
4-32

Removal of power wire
Frame
Battery
Disconnect the master power switch before
loading/unloading;
During installation, all terminals should be
mounted by strictly following the sequence
of 1~6 shown in the above figure.
Before the next step, ensure each terminal
and its bushing are tightened up reliably.
For removal, firstly disconnect the
negative circuit, namely the five terminals.
In use, care must be taken to avoid any
metallic conductor from touching the main
power switch and frame or battery frame at
the same time.
Structures descriptions and operations (B19 cab)
Operations on spare tire Operation of rear fence
Rear gate switch
Right
Tail gate handle
Push
Pull up
The spare tire is mounted at the tail of
vehicle.
Taking out of spare tire Pull the tail gate handle (each for left and
right sides) upwards along the arrow, and
• Rotate the drive lever
then forcefully open the rear gate.
counterclockwise with a wrench to
lower down the spare tire.
• Take out its carrier to draw out the
spare tire.
Putting down of spare tire
• Install the spare tire according to the
reverse procedure.
Caution: The spare tire must be
installed reliably, so as not to get lost.
4-33
Structures descriptions and operations (B19 cab)
Side gate switch 1. While slightly pressing the handle A
with your right hand, hold the limiter
pull-rod B and upper handle C1 at the
same time with your left hand, so as
Side gate to separate the hook H from the pivot
handle G, and push the handle A to the limit.
2. While holding the handles C1 or C2
Tail gate handle with your left hand, pull the safety
hook D with your right hand until it is
separated from the hook frame J, and
then roll over the cab.
3. Rotate the clamping plate E
Follow the arrow direction to open the side downwards to hook it up, and rotate
gate handle and then the tailgate handle to the circlip F upwards into the slot at
open the side gate. the root of clamping plate E.
Cab tilting (L-shape cab) Laying down of cab
Tilting actions
Release
Tilting
1. While holding the handle C1 or C2
with your right hand to support the
4-34
cab, rotate the circlip F upwards off
the slot of clamping plate E with your
left hand, and then release the
clamping plate E.
2. While holding the handle C1 or C2
with your right hand, lay down the
cab until the safety hook D is put in
the hook housing J (never move the
handle A forcefully and pay attention
to the lowering cab and handle A).
3. Press the handle A until it is locked
completely into the hook H for limit.
Cab tilting (S-shape cab)
Tilting actions
1. While slightly pressing the handle A
with your right hand, hold the limiter
pull-rod B with your left hand, so as

to separate the hook H from the pivot
G, and push the handle A upwards to
the limit.
2. While holding the handle C with your
left hand, pull the safety hook D off
the hook housing J with your right
hand, and then roll up the cab.
3. Ensure the clamping plate E is
reliably locked up, rotate the circlip F
downwards into the slot at root of
clamping plate E.
Laying down of cab
Release
1. While holding the handle C with
your right hand to support the cab, rotate
the circlip F upwards off the slot of
clamping plate E with your left hand, and
then release the clamping plate E.
Structures descriptions and operations (B19 cab)
2. While holding the handle C, lay down substance, is very easy to explode under
the cab until the safety hook D is some circumstances. Improper use or
connected reliably with the hook operation may cause fire burn or other
housing J. serious injuries. When refueling, please
3. Press the handle A until the hook H shut down the engine, do not smoke
reliably clasps the pin G of handle A. around vehicle. Any flame or fire is not
allowed.
Danger: whenever the cab is rolled over,
the circlip should be fastened reliably. Danger: the fuel tank has a certain
pressure. Before it is opened, rotate the
Precautions for cab tilting oil filler cap for half a turn till the hiss
• Park the vehicle on the as flat ground disappears.
as possible. Danger: if any fuel splashes onto vehicle
• Always pay attention to that there body, immediately wash the body to avoid
should be sufficient clearance the damage of paint.
between the ceiling top and front
wall.
• Ensure the parking brake is in
working state.
• Shift the gear lever of transmission to
the gear N.
• Wedge each wheel if needed.
Caution: All the bits and pieces in cab
should be packed up and the objects
possible to fall down should be removed.
Fuel tank
Danger: the fuel, as an inflammable
4-35
Structures descriptions and operations (B19 cab)
Open or lock the fuel tank cap insert and turn clockwise the key by
90° to lock the fuel tank cap. Then,
pull out the key.
Precautions for fuel filling
Caution: When the fuel gun stops, the
fuel gauge may not show the full level
and the fuel tank may be not fully filled
either, and refuel the tank as the case
may be.

Locking of Close
fuel tank

Open

Rotating angle of
key Unlocking of fuel tank
1. Open the lock hole cap;
2. Insert and turn counterclockwise the
key by 90°to unlock the fuel tank cap
and then rotate counterclockwise the
fuel tank cap to open the cap;
3. Tighten clockwise the fuel tank cap,

4-36
 Structures descriptions and operations (B19 cab)

Fuse case
The fuse box cover inside is attached with the nameplate showing Fuse
the fuse model. This nameplate can be referred when the fuse is
replaced.

Fuse case

To repair the fuse box, just pull out the cover directly.
Danger: the horizontal storage box cannot be wetted, so as to
prevent the water from entering the instrument panel through the
1. Fuse case 3. Horizontal storage box Tbox cover; otherwise, the fuse box and main circuit may be short
2. Tbox cover circuited.

4-37

Driving vehicle
Startup of engine
Precautions before engine
startup
 Check the engine oil and coolant
level;
 Check the fuel level in the fuel
tank;
 With no air cleaner, the engine is
prohibited to work;
 For the new vehicle or the
vehicle being parked for long
term, use the hand pump of fuel
supply pump to drain the air out
of the fuel supply system. It is
prohibited to drain the air by
starting the engine.
 Ensure the gear lever is at the
neutral position.
 Turn on the main power supply
switch
Normal startup
1. Turn the ignition switch to ON,
then check each warning
indicator is normally lit.
During the self-inspection of
electronic-control Euro-III
engine, the “Shutdown warning
lamp ” and “Alarm
warning lamp ” on the
combine instrument panel
simultaneously light up for 1s
and go out when there is no
failure.
2. Check whether the
“Intake-preheating indicator” is
lit or not, if not, the engine can
be started; if yes, do not start
engine until the lamp goes out.
3. Depress the clutch to the floor
and turn the ignition switch to
START to start engine.
4. As soon as the engine is started,
Driving vehicle5
release the key and slowly
loosen the accelerator pedal to
the idling position. Observe the
oil pressure within 15s.
Caution: Do not depress the
accelerator pedal switch when the
electronic-control Euro-III engine is
starting; otherwise that makes
engine harder to start up.
Caution: Starting the starter should
not last for 5s, within the interval of
at least 20s, as the long-term
starting the starter could
over-discharge the battery and
accordingly shorten its useful life.
After the engine is started, if the
charging indicator is still ON, it
means the generator does not
generate the electricity or generates
the insufficient electricity. In such
case, stop vehicle for inspection. At
low ambient temperature or in
winter, preheat the engine for
15-20s and then start it again.
5-1
Driving vehicle
Caution: In order to adequately
protect the engine and the
supercharger, please idle the engine
for 3-5min after startup or before
stop.
Caution: Do not make use of
engine idling to heat up the engine.
Besides, engine idling shall not
exceed 5min.
Caution: For the safety and in order
to reduce the starter load, do depress
the clutch pedal when starting the
engine.
5-2
Start of engine with cab
tilted
Assist-Startup
1. Pull up the parking brake handle
and block the wheel by
triangular woods.
2. Rotate the key switch to position
“ON”.
3. Make sure that the gearshift
lever of the transmission is at
neutral position.
4. Press the engine auxiliary start
button to start the engine.
5. To stop the engine, ensure to
pull the flameout cable (if
equipped) to stop the engine.
Rotate the key switch from
“ON” to “OFF”.
Caution: Do not press and hold the
start button for more than 5s and
wait for at least 20s between two
consecutive starts, otherwise it will
shorten the battery life.
Danger: While the engine is
running with the cab tilted, notice
not to touch the transmission
gearshift lever.
Danger: It’s prohibited to lower the
cab while the engine is running.
Ensure to stop the engine before
lowering the cab.
 Driving vehicle
Startup by the assist terminal of good battery 1. Driving precautions
battery 3. Connect the one end of another
booster cable (black) to the
negative pole of good battery 1
and the other to the chassis
frame of vehicle with the
powerless battery 2, as far from
the battery as possible.
4. After connection of the booster
cables, start the engine of
vehicle with the powerless The correct driving methods could
The assist battery is available to battery. If it is difficult to start not only prolong the vehicle life,
start vehicle when the battery the engine at low temperature, improve the economy efficiency, but
electricity is too low to start up the run the normal vehicle engine also greatly influence the safety
engine. for a few minutes and then start traveling. Caution:
the engine of vehicle with the  With engine still at cold station,
Steps: powerless battery. do not move the vehicle away.
1. Shut down the engine with the 5. After engine startup, disconnect
good battery;  After the cold startup, slowly
the cables in the sequence increase the engine to the
2. Connect the one end of booster reversing to connection. allowed range so as for the oil
cable (red) to the positive pressure to increase as the
terminal of powerless battery 2 engine runs.
and the other end to the positive

5-3
 Driving vehicle
 Do not move the vehicle away until the exhaust heavily loaded, try best to avoid pivot steering, otherwise
becomes the light blue. steering drag link may bend or other fault may occur.
 Do not immediately increase the engine rpm, which Danger: under the insufficiently air pressure, do not
otherwise could damage to the engine due to coolant forcefully run the vehicle.
at low temperature.
Brake operation
 If the ambient temperature is less than 0℃,before the
full-load work, run the engine at mid speed for 5min.
 About diesel vehicles,if the accumulated mileage is
less than 5000km, the engine rpm is better not to
exceed 2500r/min.
• About LIUJI gasoline vehicle,before the running
mileage reaches 1500km, engine rpm cannot exceed
4000r/min.
 Avoid full throttle to move away or sharp braking,
which otherwise may damage to the clutch, lead to To smoothly stop vehicle, refer to the following steps:
irregular wear or speed up the tire and brake friction
ling wire. 1. At the 25～35m away from the destination, depress
the brake pedal by 1/3～1/2.
 It is prohibited to travel the overloaded vehicle.
Overloading will shorten the vehicle service life. 2. At the 5~6m away from the destination, gradually
loosen the pedal.
 Ensure the air pressure gauge (air brake type) reaches
the green area; meanwhile, do not run the vehicle 3. Before arriving at the destination, slightly depress
until the alarm silence. down the brake pedal to completely stop vehicle.
Caution: When vehicle equipped with power steering is If the brake pedal is depressed down for long term,

5-4

vehicle will sharply be braked.
After vehicle being washed or
wading, brake drum may be watered,
impairing the baking efficiency.
Therefore at low-speed traveling,
press down the pedal for a few
minutes to evaporate the moisture.
Caution: do not click the brake
pedal, as that could reduce the air
pressure in air reservoir, causing
insufficient braking force.
Danger: Do not use the emergency
braking unless in emergency case,
as the emergency braking could
easily leadto rollover, especially on
rainy days.
Parking brake
Notice for engine shutdown:
• Do not shut down engine but
instead idle it for 3-5min, so that
the engine coolant could cool
down;
Driving vehicle
• Specially when the engine runs the parking brake is released, which
at heavy-duty or high speed, it is otherwise could impair the braking
a must that engine idling; performance.
otherwise, that could lead to
engine cylinder scratching or Traveling on the slope
supercharger damage.
• After the engine is shut down,
turn off all the switches,
specially the power switches.
Notice for parking
 Whenever parking the vehicle,
apply the parking brake to avoid
the vehicle from accidentally
When running downhill, activate
moving.
exhaust brake (if equipped) and foot
 Shift to any gear rather than brake to maintain the vehicle speed
neutral gear. It is suggested to is reasonable and controllable range.
shift to I gear at upslope
parking. When the low gear is engaged or at
downhill traveling, engine max. rpm
 Besides, wedge the wheels in does not exceed the 3000r/min.
order to avoid the vehicle from Engine overspeed running could
accidentally moving. mechanically damage to the parts
Caution: before traveling, ensure
5-5
Driving vehicle
subjected to the force.
Before running on downhill
whichever is steep or long, try the
brake for normal work.
At downhill driving or when the
high speed gear is shifted to the low
speed gear, check the speedometer
to confirm the vehicle speed.
Caution: at any running conditions,
the engine rpm is not allowed to
exceed 3500r/min.
Danger: Never driving on a slope
with engine shutoff.
Anti-lock brake system
(ABS) (Optional)
Use of ABS
Depress the brake pedal. Depress
the brake pedal with stable pressure
and never press it up and down.
ABS will work to prevent wheels
from locking and help driver
5-6
normally control vehicle to avoid
damage.
Danger: never press the brake
pedal up and down. Otherwise the
brake distance may increase.
Self-inspection
ABS includes electronic sensor,
motor pump, hydraulic
electromagnetic valve and processor.
Processor has self-checking
function, and it will test the system
at each engine startup and when
vehicle moves forward/backward at
low speed. When executing
self-inspection, you may hear
"metallic sound" noise and/or feel
the pulsation of brake pedal. This is
normal and do not signify any fault.
If the processor finds out any fault,
it will shut down the ABS system
and lighten the ABS brake warning
indicator on combination instrument.
At such time, brake system may
work normally but has no anti-lock
function.
If the ABS warning lamp turns on
during self-checking or driving,
please have your vehicle checked by
an after-service branch as soon as
possible.
Operate properly.
The ABS starts working when the
vehicle speed exceeds 5~10km/h,
which varies depending on the road
conditions.
When the ABS detects that one or
more wheels are nearly locked, the
actuators will work rapidly to
release the pressure. This motion is
similar to the quick depressing and
releasing of the brake pedal. When
the ABS is functioning, the
pulsation of the brake pedal can be
felt and a noise can be heard from
the engine compartment or the
vibration of actuators can be felt.
This is a normal symptom that

indicates that the ABS is
functioning normally. However, the
vibration also probably indicates
that the road condition is dangerous.
Therefore, pay special attention
during driving.
Clutch operation
 The releasing clutch must be
rapid and thorough (incomplete
separation is the major cause of
damage to clutch).
 Clutch should not be
semi-engaged, that could
directly influence the clutch
operation and useful life.
 After the clutch operation is
over, do not put your feet on the
clutch pedal.
Driving vehicle
Use of triangle warning sign system operation.
Caution: do not turn off the power 60s
after engine is shut down
In case of any failures, firstly turn
on the hazard warning signal lamp,
take out the triangle warning sign
and put it 30~100m away from the
failed vehicle. The red reflector
should face backward.
Precautions after engine
shutdown
All vehicles with Euro V
post-treatment system, the AdBlue
pump empties the pipeline when the
engine has stopped. If the vehicle is
powered off during that time, the
AdBlue solution left in the pipeline
crystallize, which affecting the
5-7

Maintenance of vehicle
New vehicle running-in
and maintenance
The correct running-in of new
vehicle could not only prolong the
vehicle useful life, but also enhance
the vehicle reliability.
Running-in mileage of a new vehicle
shall be 1,500~2,500km; however, a
new vehicle shall run at least
2,500km before regular operation,
because the vehicle dynamics is the
maximum; otherwise the engine
components may be worn at early
stage due to low power and high
load.
Before running-in
 Clean vehicle to check each part
for connection and tightness.
 Check the coolant level in the
radiator, and whether there is
leakage from cooling system.
 Check the oil level respectively
in engine, clutch control system,
gearbox, rear axle, hydraulic
brake system and power steering
gear, refill it if needed, and check
for oil leakage at each part.
 Check the each part in steering
system for looseness and stuck
phenomenon.
 Check whether the brake system
could work normally and
whether the pipeline joint is
leaked.
 Check the electrical system,
lighting and instrument for
normal working; check the
battery for the “electric eye”.
 Check whether the tire pressure
is normal.
 Check each gear of gear box can
Maintenance of vehicle
be correctly engaged.
Running-in period
The vehicle could travel at the good
surface.
Steadily engage the clutch; timely
shift to the gear; it is prohibited to
travel the vehicle with some parts
failed; do not forcefully rush the
vehicle; avoid emergency and brake.
The load capacity during running-in
period should not exceed 70% of
rated load.
Frequently pay attention to the
temperature of transmission, retarder,
axle, wheel hub and brake disc. If
any one of them is too hot, find out
the cause and timely adjust and
repair it.
Pay specially attention to the oil
pressure and control the normal
temperature of engine coolant.
6-1
Maintenance of vehicle
After running-in is over maintained every 5000km (4000km of filter element to observe for the
in dusty ). damage or small hole. Then check
After running-in, please come to
whether the washer is damaged, if so,
local agent of overseas business Every 20000km（15000km in dusty）.
replace it abnormally.
department of Dongfeng in If the external filter element is
accordance with Regular damaged or the main filter element is Inspection methods of filter
Maintenance Items specified herein. cleaned for 5 times, ensure to replace element
the main filter element.
Air cleaner
The safety filter element cannot be
cleaned. The damaged or
five-cleaned safety filter element
cannot be replaced.
Inspection methods of filter
element

Take out the main filter element, as

Air cleaner is composed of main
filter element, safety filter element,
whirlwind cover, housing and
housing cover etc. The filter element
is of paper type.
The primary filter element should be
6-2
you rotate the filter element; use the
2~3x100kPa compressed air to blow
the element form the inside to the
outside. Or slightly pad the end of
element to remove the attached dust.
Put the lighting lamp into the inside
 Maintenance of vehicle
Replacement methods of filter getting into the filter element could Inspection of thermostat
element greatly shorten the engine life.
starting temperature
1. Loosen by hand the butterfly nut Caution: During installation, check
of the air cleaner cap and remove whether each seal is intact, if
the cap. damaged, replace it. Besides, each
seal should not be lost or omitted.
2. Unscrew the fastening nuts of
filter element and remove the Caution: During installation, the
filter element. dust cover must face downward.
3. Install the parts in the sequence Draining coolant out of
reverse to the removing cooling system
procedures.
In winter, if the vehicle is not used Every 50000km use the hot water to
Caution: it is prohibited to remove for long term, and is not filled with check the thermostat working
the air cleaner as engine runs. antifreeze fluid, timely drain the conditions.
Caution: never use the gasoline or coolant to prevent cylinder block and The thermostat opening temperature
any fluid to wash the filter element. radiator being frozen. Besides, the is 76℃ and 86℃.
Caution: during cleaning the drain valve is located at the coolant
reservoir below the radiator. The full-open travel of thermostat is
whirlwind cover, replace the equal to or higher than 6mm (3-5min
damaged one. Caution: with engine at hot state,
in the boiling water).
Caution: Ensure the filter element uncap the radiator slowly to relieve
the inside pressure to avoid the hot Caution: The thermostat is of great
and whirlwind cover are already influence to maintain the normal
installed in place; otherwise the air coolant from ejecting.
running of engine and reduce the

6-3
Maintenance of vehicle
wear of various engine parts and
shall not be disassembled at will.
Water-draining port on
the water pump
There is a water-draining port
beneath the water pump block, so
that the leaked water from the water
seal could pass through this pore.
Therefore, it is not allowed to plug
this pore, otherwise, the water will
be accumulated in the chamber, then
soak the bearing and then damage to
Venting the fuel system
With engine stopped, to drain the air
out of the fuel supply system, use the
there is fuel flows out, with no
bubble.
4. Then tighten the bolt and screw.
At the same time, tighten the
manual oil pump handle.
Caution: for the engine with the
electronic-fuel-injection control, it is
unnecessary to drain the air by
loosening the pressure pipeline.
Exhaust turbocharger

it.
With the vehicle parked, if the water
continues dropping from the pore,
dismantle the water pump to repair
the water seal.
Oil inlet
hand pump on the fuel pump. The
method is as follows:
1. Rotate outward the hand pump
handle, and repeat pressing and
lifting the handle to supply fuel
to the fuel system.
2. Loosen the vent screws on the
small oil return pipe of the fuel

Oil return
opening
filter and the fuel injection pump;
3. Continue to press and lift the
hand pump to supply fuel until The lubricant in the supercharger is

6-4

supplied by the engine main gallery
and goes to the oil sump under dead
weight. In order to avoid the
supercharger leaking and to ensure
the supercharger works normally and
reliably, pay attention to that the fuel
inlet and outlet pipeline must be
smooth, with not leakage. Besides,
the cross section and shape of fuel
return pipe should not change.
As the supercharger is of
sophisticated high-speed rotating
parts, do not dismantle it without
authority. When the too much dirt or
accumulated carbon sticks to the
rotator or deteriorate the engine,
simply clean or wash it under the
conditions of supercharger not
completely dismantled. The method
is as follows:
1. Remove the dust or oil
contamination on the surface of
supercharger.
Maintenance of vehicle
2. Remove the supercharger from detergent may use kerosene, gasoline,
the engine. Do not push the link or high quality diesel.
(serving as the handle) to lift the
supercharger. Air dryer (If equipped)
3. Firstly remove the air guide pipe
and then the vent valve adjuster.
4. Remove the air compressor
housing, turbine housing and oil
inlet/outlet flange.
5. Clean and wash the air
compressor housing, turbine
hosing and two vanes.
6. Fill the proper and clean
detergent into the oil inlet filler,
meanwhile, manually rotate the
vanes until you feel smoothly.
7. Reinstall it on the engine.
Check if there is water in the air
Caution: Never impact the impellor reservoir every 100000km, and
during disassembling, assembling, change the drying agent if needed.
and cleaning. In event of collision,
it’s prohibited to correct any
deformed vane for reuse. The
6-5
Maintenance of vehicle
Oil filter
Initial maintenance: 1500~2500km
Change interval: 10000km
The spin-on engine oil filter for the
engine is of one-time type and shall
be replaced integrally.
The filter should be changed every
10000km (or 250h) with the special
filter wrench. The new one to be
installed should be firstly filled up
with the clean engine oil and the
rubber ring after coated with the
engine oil should be adequately
tightened up. Then start up the
6-6
engine to check if the seal leaks; if so,
continuously tighten it up until it
does not leak.
Caution: it is not allowed to tighten
the filter using a wrench for
installation. Otherwise, that could
damage the filter.
Fuel prefilter
Plug
The fuel prefilter is fixed the low
pressure fuel pipe between the fuel
tank and fuel supply pump with the
prefilter stand.
Take down the screw plug to drain
the water out every 10000km.
Change the diesel strainer assembly
every 20000km.
Fuel filter and fuel-water
separator
1. Fuel filter 2. Drain
3. Fuel-water separator
Change every 10000km (or 250h).
Use the special filter wrench to
remove the fuel filter and the
fuel-water separator for replacement.
The new fuel filter and the fuel-water
separator to be installed should be
filled up with the clean fuel, then
manually set up until the seal fits the
 Maintenance of vehicle
interface, and lastly further tightened fuel tank Use and maintenance of
up by 3/4 cycle.
SCR system
Caution: do not use any wrench to AdBlue pump components
AdBlue tank
tighten the fuel filter and fuel-water
separator for installation; otherwise
that may damage to the threads and Compressed
filter. air filter

Caution: An electronically Oil-drain plug Temperature Anti-freezing solution solenoid valve

sensor after
controlled fuel injection engine shall NOx sensor catalyst
Temperature sensor before catalyst

Nozzle
choose the fuel-water separator and
fuel fine filter designated by the After the fuel tank is used for long
manufacturer. It’s especially term, periodically (generally every Catalytic muffler

prohibited to substitute by a common 10000km ) remove the plug beneath

paper filter. the fuel tank to drain the water and
Manufacturers of fuel-water foreign material out of fuel tank. As
separator: Fleetguard and Parker soon as the clean diesel flows out,
(designed by DFAC and assembled tighten the plug. In winter, do drain
on finished vehicle) the water to prevent it from freezing,
blocking the fuel supply.
Manufacturer of fuel filter:
Fleetguard (installed on engine and
designated by engine manufacturer)
Drain the water out of
6-7
Maintenance of vehicle
AdBlue reservoir (if
equipped)
AdBlue solution
AdBlue could catalytically reduce
the NOX coming from the engine
exhaust system at high temperature,
generating the nitrogen and water
vapor. The AdBlue consumption is
equal to 5% -7% of fuel consumption
and therefore should be properly
added.
The mounted intelligent electronic
system could accurately control the
6-8
AdBlue injection according to the and should be added at the nearby
engine load/running, improving the station if needed.
entire fuel economy and the engine Caution: the AdBlue consumes very
power and reducing the exhaustion. little when vehicle runs at the
Precautions for operations: extremely low speed or stands still.
Caution: Never use fuel containing In the hot climate, it is suggested to
much Sulphur. protect the AdBlue reservoir from
Caution: copper, brass, low-carbon the direct sunshine.
steel or zinc shall be applied to Maintenance and
where there is AdBlue.
repairing of metering
Caution: Urea solution is
transparent liquid, has light
injection pump
ammonium hydroxide smell and
strong corrosivity to some materials,
including soft metal and certain
polymers. It is a must to avoid flash
to prevent the potential corrosion so
as to avoid the need for cleaning the
salt slag left after moisture
evaporation and prevent urea from
entering sewer and riverway. AdBlue solution filler port
Caution: The AdBlue consumes at No daily maintenance is required for
5% -7% of diesel consumption rate metering injection pump under

normal use condition. Filter screen
equipped at the filler port of pump is
mainly used to keep out large foreign
matters. If the filter screen at filler
port is found blocked by plenty of
foreign matters or liquid flow is
seriously affected thereby, it is only
required to take off the whole filler
port joint (wherein the filter screen
for filler port is inserted), purge it
with compressed air along the
direction against the flow direction a
t filler port, then reinstall the filler
port joint to recover normal use. Or
use tweezers or other tools to take
out large foreign matters to recover
normal use.
Compressed air filter
Air source of compressed air filter
after being filter by the air filter of
engine has very few impurity content.
If due to air filter damage etc.
reasons, too much foreign matters
Maintenance of vehicle
are accumulated inside compressed servicing of nozzle
air filter, it is permitted to take off
filter tube and clean the filter In event of blockage of nozzle,
element by reverse purging; or immerse the nozzle within 50~60ºC
directly replace new compressed air purified water. If the malfunction is
filter. not solved after 6 hours of
immersion, replace the nozzle.
Caution: During daily maintenances,
check the glass window of Manual engine water valve
compressed air filter for accumulated
water. Upon detection of
accumulated water, drain timely.
Maintenance and
servicing of temperature
sensor and nitrogen
oxygen sensor
Two sensors are maintenance free,
users shall not provide maintenance
When the ambient temperature
and servicing, if fault occurs, ask
exceeds 17°C, the manual engine
professional maintenance personnel
water valve is closed (as shown
for treatment.
above).
Maintenance and
6-9
Maintenance of vehicle
Check the engine lubricant 1. About 5min after the engine
height flameout, take out the dipstick,
use the clean cloth to wipe it and
reinstall it.
2. Take it out again to observe the
oil level height.
3. The normal oil level should be
between the two scales, and fill
or drain the clean lubricant if
When the ambient temperature drops needed.
to 17°C or less, open the manual Caution: do not check the oil level
engine water valve (as shown above), until the engine cools down.
prompting the vehicle to provide the
Replacement method:
hot water to the Post-treatment heat
system.
Engine lubricant
1. Dipstick
Date of change:
Periodical replacement: 10000km

1. Remove the plug beneath the oil

6-10

sump to completely drain the oil
out of oil sump when the engine
is still hot.
2. Wipe the plug and reinstall it.
3. Replace the oil filter and clean
the seal joint surface of filter.
4. Refill the new lubricant as
stipulated.
5. Start the engine and then idle it,
and then observe whether the
filter and oil drain plug are
leaked.
6. Switch off engine and wait for
5-10min, check whether the oil
level reaches the normal range.
Caution: do not drain the lubricant
until the engine is moveless.
Inspection and filling of
oil level in clutch oil
reservoir
Release
Unlock
The clutch oil reservoir is inside of
cab. Generally, the oil level should
be between the lower scale mark and
reservoir block, and replenish it if
needed.
Before refilling, check the pipeline
system for leakage. If so, repair it
before replenishment.
Caution: do not use the brake fluid
with the quality or model different
Maintenance of vehicle
from the original one. Never use the
mineral oil as the brake fluid.
Caution: Ensure to use the clean
brake fluid.
Caution: The brake fluid does not
touch any painting surface to avoid
damaging to it.
Caution: As the brake fluid could
easily absorb the moisture in air, seal
the brake fluid for storage.
Caution: The dirt or dust does not
enter the brake and clutch oil
reservoir. Before replenishing or
changing the oil, ensure the
surroundings of oil reservoir are
clean.
6-11
Maintenance of vehicle
Inspection, refilling and
change of lubricant in the
gearbox
Vent plug
Oil drain plug
Engine oil filling and oil dipstick
Check the transmission lubricant
level every 5000km. To check the oil
level, firstly uncap the gearbox and
remove the plug to check whether
the oil arrives the lower edge of plug,
refill it if needed. Meanwhile, check
the vent plug for working state and
clean it if needed.
Change the transmission lubricant
before vehicle cooling down every
20000km. Firstly screw off the drain
6-12
plug to completely drain the oil out Inspection, refilling and
of gearbox, clean the plug (as the
magnet in the plug could attract the change of lubricant in the
iron powder in the oil) and then final drive of rear axle
reinstall it. Refill the new lubricant
through the oil filler port.
Caution: Insufficient oil could burn
the bearing and gear and too much
oil could leak.
Caution: Always keep the vent plug
smooth. To fill the lubricant, do not
have the foreign material such as
dust enter the gearbox.
1. Access plug 2. Drain plug
Check the primary transmission
lubricant level every 10,000km.
Screw off the drain plug to check
whether the oil reaches the lower
edge of hole, refill it if needed.
Check and clean the breather.
Change the primary transmission
lubricant level every 20,000km.
Firstly screw off the oil-drain plug to
drain the lubricant. Clean the oil

drain plug and reinstall it. At last
refill the new lubricant through the
oil-filler port.
Caution: Add lubricating oil as per
the specification and never substitute
with common gear oil, or it will lead
to rapid scratch and wear of the gear
tooth faces.
Caution: During filling oil, keep the
dust or dirt away from the final
drive.
Caution: Keep the level at the
normal rather than too high or too
low.
Caution: Always keep the vent plug
smooth.
Inspection, filling and
replacement of power
steering gear oil
1. Oil filler cap with dipstick
Maintenance of vehicle
2. Hydraulic oil filter element
3. Oil reservoir
Before checking the power steering
oil level, park the vehicle on a level
ground, stop the engine, tilt the cab,
and wipe clean the oil reservoir.
After that, screw down the oil filler
cap and the dipstick assembly, wipe
the dipstick and the reinstall it. Take
it out again to observe the oil level.
If the oil level is out of the normal
range, refill the hydraulic oil with the
same model till the upper marking of
the oil dipstick.
Before adding the oil, check the
pipeline for presence of leakage.
Check the steering gear lubricant
level every 5000km and add it to the
oil filler edge if needed.
Change the power steering system
fluid every 20000km.
Replacement method of power
6-13
Maintenance of vehicle
steering oil:
1. Block both front and rear of the
rear wheels by triangular woods,
shift the transmission to neutral
gear, and elevate the front shaft
by a jack till the tires on two
sides are off the ground.
2. Unscrew the oil inlet and outlet
pipe connectors of steering gear
and fully drain the oil from
steering system. Start the engine
and rotate the steering wheel
back and forth.
3. After ensuring that the system oil
is fully drained, open the top cap
of oil reservoir, top up the oil
reservoir, start and run the engine
for a while, and then stop the
engine and add hydraulic oil
again. Repeat above operations,
till the hydraulic oil level is
between upper and lower
markings of the oil dipstick.
6-14
Caution: Do not turn in situ in case
of heavy loading, otherwise the drag
link and tire may be worn at early
stage.
Caution: during steering the vehicle
in situ, do not have the steering
wheel at limit position for long time
(more than 15s), which otherwise
could overload the oil pump etc.
Maintenance of wheel hub
bearing
Service the wheel hub bearing every
10000km. Remove the wheel hub
and brake drum, clean the wheel hub
bearing, remove the deteriorated
grease in the chamber of wheel hub,
and then refill the space between
race of bearing and retainer with the
new grease, at last apply the thin
layer of grease inside and outside of
bearing.
Caution: After the disassembling of
wheel hub, ensure to timely replace
with new oil seal upon detection of
oil seal damage. Before the
installation of wheel hub, apply some
lubricating grease onto the lips of oil
seal.
Brake pedal travel
 Slightly press down the brake
pedal to check whether the free
travel is≤ 40mm
 Check whether the brake pedal is
stuck or not.
• The air-draining sound should be
heard as the pedal is being
released.

Draining water out of the power supply, the battery poles
should be applied with a thin
air reservoir layer of grease (Vaseline) to
avoid oxidation and corrosion.
 In order to connect or disconnect
the battery wire, do not hit or pry
the battery poles, use the air
pressure gun to tighten the bolts.
 The pull rod and mound layer for
fixing the battery frame should
be properly tightened, as they
being loose cannot fix the battery
After the work is over each day,
drain the water of the air reservoir, and being too tight could deform
specially the wet air reservoir. Pull the battery, crack the sealing
the water drain valve beneath the air adhesive or leak the electrolyte.
reservoir outward to drain the water.  To remove the battery, firstly
remove the negative pole of
Operation and battery and the positive pole; to
maintenance of battery install the battery, the sequence is
reverse to the removing one.
Precautions for installation of
battery Vehicle storage
 Before installing the battery 1. Before storing the vehicle, close
Maintenance of vehicle
the doors, turn off the electrical
elements such as the lamps, and
then the main power switch.
2. To store the vehicle for long term
(more than half month), it is best
to remove the negative pole of
battery to avoid the battery
lacking of electricity due to
electrical parts long working. It is
best to start the engine and run it
for 10-15min every month to
charge the battery.
3. Avoid the frequently start the
engine and idle it for long term,
which otherwise could damage to
the battery or lead of battery lack
of electricity.
4. If the poles are corroded by the
oil contamination or dust, use the
cotton cloth to clean the poles, in
order to avoid the high contact
resistance at cold start from
burning the pole or leading to
6-15
Maintenance of vehicle
poor startup.
Use method:
1. Before using the battery,
measure the voltage of battery.
The battery can be directly used
if the measured value is higher
than 12.6V, otherwise, recharge
it before use.
2. For the liquid-sealing battery
equipped with the electricity
indicator (also known as the
“Electricity Eye”), refer to the
related instruction on the battery.
Charge the battery if lack of
electricity before use.
3. The “+” and “-” poles of
battery should be respectively
connected to the positive pole
and negative pole of vehicle, or
reverse connection could damage
to the electrical parts. Besides, in
order to protect the automobile
engine, do not start the engine
6-16
until the battery is properly
connected.
4. The liquid-sealing battery is not
allowed to be tilted or
transported or used upside down.
Maintenance
1. The liquid-sealing
maintenance-free battery if
stored for 3 months or more
should be charged.
2. Frequently check whether the
vent holes at the both sides of
battery upper cover are blocked
by the dust or ice, otherwise, the
housing will be deformed or
cracked.
3. The battery should be kept
away from the hot source and
open flame, and should be
charged or used at ventilated
conditions. Be carefully, the
electrolyte may explode,
causing the personal injuries.
4. Before storing the battery or
vehicle, fully charge the battery,
which otherwise could shorten
the battery useful life.
Charging the battery:
constant voltage
1. Constant voltage: for the
liquid-sealing maintenance-free
battery, the charging voltage is
14.4 ± 0.2V and allowed max.
current is 0.5C20( C20 means
the battery capacity at charging
for 20h.). Charge the battery
until the current approaches the
zero and then hold it for 2-3h.
2. Constant current: Charge the
battery at the current of 0.1C20A.
When the change of voltage is
less than or equal to the 0.05V/h,
the battery has already been
completely charged.

Fuse
Normal Burnt
Before changing the fuse, check the
fuse current specification. If the new
fuse is easily be burnt,find out the
cause and repair it. If it is impossible
to solve the problem, contact with
dealer of overseas business
department of Dongfeng.
Caution: Never use the common
wire or fuse with different current
value to replace the blown one.
Danger: It is prohibited to connect
the wire in fuse for power output.
The fuse to be installed should have
Maintenance of vehicle
the same capacity as the last one, harness or any part of positive wire
otherwise which could possibly catch overlaps the exhaust pipe.
fire.
Suspension
Inspection of wiring
harness U bolts
At serving the vehicle, check
whether all wires are reliably fixed
(Criteria: the wire cannot come off
the harness during traveling. ).
Clamp
Ensure there is no friction between
the wiring harness and other parts.
The clearance between the harness
and movable parts should be more After running-in, refer to the
than or equal to 50mm and the stipulated torque to tighten the U
clearance between the harness and bolts and nuts attached to the leaf
engine exhaust pipe should be equal spring.
to or more than 100mm. Every 10000km, tighten the leaf
Caution: Please reliably fix the spring U bolts and nuts or fixing nuts
battery positive wire together with attached to the steering system.
the harnesses around the engine
exhaust pipe.
Danger: it is prohibited for the
6-17
Maintenance of vehicle
Wheel rotation
Tire rotation should be done every
10000km according to the schematic.
Principle of tire rotation:
 For the dual tires of rear axle,
the difference of outside
diameters of two tires should be
equal to or less than 12mm. The
tire with smaller outside
diameter should be installed
inside.
 The front wheels should be of
same model, balance and less
wear;
6-18
• The rotated tires should run in  Check whether the wheel rim is
the reversing direction; cracked or not, if so, replace it.
 The new tires should be used in  During installing the dual tires,
pair. the valves of dual tires should
 On the same axle, only tires with stagger for convenient inflation.
same dimensions, specifications, Tyre replacement
treads and pressures can be
installed, which otherwise could Remove the tires
lead to braking deviation,
vehicle-body swing and
out-of-control steering.
 Check whether the wheel hub
bolts and nuts are scratched. For
the sake of safety, if the thread
of some nut is damaged, the nuts
should be replaced in pair.
 Check whether the wheel rim
contact surface (sphere) and
mounting holes are deformed or
damaged, if so, replace it.
 If the sphere of wheel nut is
damaged, replace it.

1. Before removing the tires (rear
wheels), wedge the front and
rear portions of rear wheels;
2. Use the wheel nut socket
wrench to loosen the nuts.
3. Jack up one end of axle slightly
free of ground.
4. Remove the wheel nuts
5. For the dual tires, lower the axle
to the original position, loosen
the inside wheel nuts and then
jack up the axle to let the wheel
free of ground.
6. Remove the wheel nuts and
inside tire.
Install the tires
1. Use the crowbar to sleeve the
wheel hub bolts into its hole on
the wheel rim.
2. Adjust the wheel hub bolt to
center position of bolt hole and
then tighten the nut.
3. Slowly lower the jack to have the
tire contact with the ground.
4. Tighten the wheel nuts by the
three-step way to the stipulated
Maintenance of vehicle
torque.
5. For the dual tires, in such case,
jack the axle again slightly free
of ground, then refer to the above
mentioned method to install the
outside tire.
6. If the only outside wheel is
removed, firstly torque the inside
wheel nuts to the specifications
and then install the outside
wheel.
Inspection of tire pressure
and tread
 Use the air pressure gauge to
measure whether the air pressure
meets the specifications, if not,
inflate it again.
 Check the tire tread depth, with
the tire wire mark as reference.
Do not use the tires exceeding
the wire mark.
6-19
Maintenance of vehicle
Clean and replacement of wiper blade Replace the wiper blades
If the wiper blade yet could not clean the window,
replace it. The concrete steps are as follows:
Keep it 1. Pull outward the wiper arm;
Push pressed
2. Take out the lock pin to remove the wiper blade.
Lock pin Remove the 3. Push the new blades into the wiper arm until you
wiper blade
hear the “click ” sound.Adjustment of vehicle

Clean the wiper blade

If the window after being wiped by the wiper is not yet
clear, maybe the wiper blade is dirty. In such case, clean
the wiper blades, with method shown below:
1. Use the washing fluid or special detergent to clean
the windshield.
2. Use the cotton cloth soaked with the special washing
fluid or detergent to clean the blades.
3. Use the clean water to wash the detergent or washing
fluid.

5-20
 Maintenance of vehicle
EURO-VI aftertreatment Requirements on China-VI consumed to 20%, it shall be
engine diesel, Adblue and replenished through its filler that
system must meet EN DIN70070. In
engine oil
Schematic of China-VI Engine addition, the filler port of Adblue
1. The China-V or above diesel cannot be confused with the fuel
Aftertreatment System shall be used in the engine, with tank filler.
the sulfur content less than
10ppm. 2. When the Adblue gauge on the
instrument panel sends out the
2. If the Adblue falls to 20% of its warning signal, the Adblue shall
capacity, replenish the Adblue be replenished immediately:
that is in compliance with the GB supposing the Adblue level is low,
29518. SCR fault indicator lights up and
1. Adblue tank gives out audible signal until the
3. Use of 15W/40ACEAE9 or API
2. Metering injection pump Adblue is replenished. Due to
CJ-4 engine oil
3. Adblue filler lack of Adblue, the engine power
4. Adblue nozzle Disqualified diesel, Adblue or engine will be limited for protection.
5. Intelligent high-temperature sensor oil may damage the metering Before replenishment, the filler
6. Reserved PM sensor injection pump and scrap the catalyst port shall be cleaned with wet
7. NOx sensor (Two pieces)
by poising it. cloth if needed.
8. Pressure difference sensor Maintenance of Adblue tank 3. The added Adblue in its reservoir
9. DOC shall confirm to the GB 29518,
1. The highest level in the Adblue
10. DPF as any disqualified Adblue may
reservoir is at the level where the
11. SCR Adblue is added to the 100% of damage the metering injection
capacity. When the Adblue is pump and scrap the catalytic

6-21
Maintenance of vehicle
converter by poising it.
4. The drain valve at the bottom of
Adblue reservoir shall be
removed annually to remove the
deposed pollutants and grease out
of the Adblue reservoir.
5. Check if the vent pipe (pore) is
blocked where appropriate, and
any found white crystal or
blockage shall be removed with
clean water. Replace the vent
pipe if needed,
6. Check and clean the antifreeze
filter on the Adblue reservoir
before winter comes.
Operation and maintenance of
metering injector
Operation of metering injector
The metering injector is composed of
integrated Adblue pump, Adblue
reservoir and antifreeze solenoid
6-22
valve. The Adblue reservoir that is
used to contain Adblue is integrated
with the Adblue pump at its bottom,
and exposed portion of Adblue
reservoir shall be covered against
any stone or mud for protection. The
Adblue pump is equipped with
Adblue level, temperature and
quality sensors that monitor the
Adblue height, temperature and
density. The Adblue reservoir
operating in cold regions are
mounted with heaters that can melt
the frozen Adblue near the Adblue
pump until the Adblue injection
system works normally. In addition,
the top of the Adblue reservoir is an
antifreeze joint and solenoid valve to
ensure the Adblue frozen in its
reservoir can be melted normally.
Maintenance of metering injector
1. The filter element of metering
injector shall be replaced every
200000km or 2 years (whichever
comes firstly)
2. Check and clean the antifreeze
filter before annual winter
comes.
3. As soon as the Adblue gauge on
the instrument panel alarms, the
Adblue shall be replenished.
4. Before filling, check if the filler
port of Adblue reservoir is clean
and wipe it with wet cloth if
needed.
5. Open the drain valve at the
bottom of Adblue reservoir
annually to remove the pollutants
and grease out of the Adblue
reservoir.
6. Check if the vent valve is
clogged, and clean or replace it if
needed.
7. Check if the water and Adblue
pipes are twisted.

Operation and maintenance of
exhaust purging muffler
Operation of exhaust purging muffler
The exhaust purging muffler is
integrated with the DOC catalyst,
DPF particle trap, SCR catalyst and
exhaust muffler. The housing is
enclosed and made of stainless steel,
and contains DOC, DPF, SCR
catalyst unit and muffler pipeline.
Below the stainless steel plate is the
heat-insulation material, and interior
catalytic unit absorbs the HC, CO,
NOX, PM and other harmful
substances in the diesel exhaust.
Maintenance of exhaust purging
muffler
1. It is necessary to keep the
insulation material of exhaust
system intact. If the insulation
material is lost on the surfaces of
exhaust manifold, supercharger,
exhaust pipe (from the
supercharger to exhaust purging
muffler) and exhaust purging
muffler, the DPF passive
regeneration capacity will
decrease, and thus the
low-temperature active
regeneration and starting &
parking regeneration need to be
triggered frequently, consuming
more diesel and Adblue..
2. The mixer shall be disassembled
each year to check if it is
crystallized, and remove the
crystal if needed.
3. Check if any sensor harness is
displaced and the sensor surface
close to the catalyst is burnt.
DPF cleaning and maintenance
Because incombustible ash may be
left after the DPF regeneration, the
ash shall be removed out the DPF
unit at the service stations every
240000km. In case of engine failure
Maintenance of vehicle
such as engine oil burning and DPF
blocked thoroughly, go to the service
stations for repair. In both cases, the
DPF shall be unclamped at both ends
and then taken down to remove the
soot and dust up to 90% if a special
equipment is adopted.
Solutions taken by users for
China-VI DPF lamp being ON
1. If the DPF indicator is kept ON,
it means the DPF soot is so
accumulated as to almost block
the DPF. In such case, a driver
shall take measures as soon as
possible to avoid the DPF further
blockage, as follows: (1) Drive
the vehicle on an expressway for
30min (2) Perform the parking
regeneration at the next stop.
2. If no measures is taken, the DPF
indicator will flash, indicating
the DPF has been clogged, and
the engine will enter the torque
limit mode (after stop) in a
6-23
Maintenance of vehicle
certain mileage. In such case, the
parking regeneration is needed as
soon as possible to avoid the
DPF from being further clogged.
3. If no measures is taken, DPF
indicator will flash and
meanwhile the yellow warning
indicator of engine will light up
in a certain mileage.
4. If no measures is taken, the DPF
indicator will flash and the red
warning indicator of engine will
light up in a certain mileage,
meaning that DPF has already
blocked and engine enters the
mode of “Limp Home” (after
stop). In such case, immediately
drive your vehicle to service
station for repair.
Parking regeneration method
A driver or serviceman checks the
diesel level is higher than 20%; after
6-24
the vehicle warm-up, stop the vehicle or serviceman can turn off the
in a safe area, release the accelerator ignition switch, shutting down the
pedal and shift the transmission to engine.
the gear N. A safety rear is defined as
a site where there is no inflammable
and person below and behind the
exhaust pipe 10m, in particular the
exhaust purging muffler. After
pressing the DPF regenerative button,
the engine control system controls
the engine to enter the parking
regeneration mode. At this mode, the
engine speeds up almost to the max.
torque automatically from the idling,
and the thermal management system
of exhaust increases the exhaust
temperature to 550℃ or above,
burning the internal soot of DPF. At
the same time, the controller will
automatically detect the efficiency of
DPF regeneration which lasts approx.
30min. After that, the engine
automatically returns to the idling
and DPF indicator goes out. A driver

in severe conditions.
Adjustment of vehicle  Merely the designated or
recommended oil model or
Precautions of parts of specifications can be filled and
engine environmental changed periodically.
compliance.  Refer to the climate conditions
 If the engine lead seals are to fill the high-quality diesel,
removed with no authorization, and do not use the inferior
Dongfeng Automobile Co., Ltd diesel.
will regard as the warrantee  Keep the coolant or lubricant
invalid. proper.
 As the engine has been adjusted  Check the supercharger,
before delivery in accordance intercooler and exhaust/intake
with national environment pipes for tightness. There should
regulations,user shall not change be no leakage.
or adjust the engine without
 In order to ensure the engine
permission; otherwise the
with supercharger can work
warranty clause will be invalid.
normally, before moving the
Provisions to be followed vehicle away, idle the engine for
3-5min in order for the each part
during maintenance of engine, specially the
 Service the three filters supercharger, to be sufficiently
periodically or more frequently lubricated. After engine is started,
Adjustment of vehicle
do not depress down the
accelerator pedal to preheat the
coolant. Before switching off the
engine, idle it for 3-5min to cool
the each part of engine down,
specially the supercharger,
which could prevent the
lubricant from gluing the hot
parts or carbon accumulating on
the hot parts.
 Use the designated oil filter and
diesel filter elements.
 Refer to the manual
requirements to check the
clearance of valves.
 Idling speed has been set, and it
is prohibited for the user to
adjust it with no permission.
Adjustment of idling could
accelerate the smoke intensity
out of limit.
7-1
Adjustment of vehicle
Tension of fan belt
Frequently check the belt tension,
with methods shown below: figure
the mid of belt span with force of
20~40N, the defection should be
10~15mm, otherwise, adjust it. The
belt too tight could prematurely
damage to the water pump bearing
and generator bearing; the belt too
loose could easily slip, reducing the
cooling efficiency and overheating
the engine.
Fan belt tension can be adjusted by
the way of the relative position of
7-2
generator to the adjusting arm. the push rod by 0.2~0.7mm
(1/7~1/2 turn) and then tighten
Clutch adjustment (with the lock nut.
clutch booster) 2. Adjust the clearance between
booster push rod and piston to
3~5mm as per same method.
3. After above adjustment, the free
travel is 20~24mm and
17~20mm respectively for the
master cylinder and booster push
rods. The free travel of clutch
pedal is 30~40mm.
1. Master cylinder 2. Booster
The clutch adopts the hydraulic
control system of master cylinder
and booster. Adjustment method of
pedal:
1. Loosen the lock nut of master
cylinder push rod and rotate the
push rod towards the piston.
When the push rod comes into
contact with the piston, retract

Draining of clutch (with
vacuum booster)
1. Drain hose 2. Drain bolt
3. Fluid reservoir
It is necesary to drain the air, as the
air hinders the clutch control system
from working normally. Method to
drain the air:
1. Fill up the clutch fluid reservoir
with the brake fluid until the
reservoir pressure reaches 650kPa.
2. Remove the booster dust cap and
the drain bolts, and then
repeatedly depress the clutch
pedal until there is bubble
emerging in the reservoir.
3. With the drain plug tightened,
repeatedly depress the clutch
pedal, and then depress the clutch
pedal to loosen the drain bolt
until the air completely gets out.
After that, tighten the drain plug
and loosen the clutch pedal.
4. Repeat the step 3 until no bubble
comes out of the drain plug,
clutch feeling completely released.
Caution: Do not forcefully tighten
the breather. Breather sealing strip
will be damaged if the breather is
tightened too highly, causing air
leakage.
Caution: When using the plastic
pipe to drain the air, the pipe end in
the bottle is not allowed to be higher
than the brake fluid.
Adjustment of parking
Adjustment of vehicle
brake travel (Central
drum type) optional
Lock nut
Lock nut of cable shaft
Check the performance of parking
brake during maintenances at
interval of 5,000km. When the
parking brake handle is pulled up to
sound for 7~9 times, the parking
brake shall keep the vehicle
stationary against startup. It indicates
that the parking brake works
normally, otherwise the adjustment is
required for the parking brake. The
adjustment method is as below:
1. Horizontally park the vehicle and
7-3
Adjustment of vehicle
block the wheels with triangular
woods.
2. Lower the handle to the lowest
position, rotate the flexible shaft
adjustment nut to form one 15º
angle between rocker arm and
ground, and tighten the lock nut.
3. Pull up the handle to sound for
7~9 time, tighten the adjustment
nut of parking brake handle to
position the parking brake at
completely locked status, and
check whether the parking brake
performance meets the requirement.
If yes, tighten the lock nut.
4. When the parking brake handle is
completely released, the parking
brake shall be free of heating
phenomenon during the driving
of the vehicle.
Manual adjustment of
service brake (air brake)
7-4
(if equipped)
Check and adjust the brake clearance
during maintenances at interval of
10,000km.
Clearance between the brake drum
and the brake shoe friction lining:
Middle of brake shoe: 0.70mm
Partial adjustment
When the clearance between brake
drum and brake shoe friction plate
exceeds the above range, it’s
necessary to adjust the worm of
adjustment arm.
1. Rotate the head of adjustment
arm worm to push inward the air
chamber push rod, till the head
can’t be rotated further. Then,
rotate backward to sound for 3~4
times.
Caution: While adjusting the
clearance of brake drum, it’s
prohibited to loosen the locating
screw of locking sleeve on the
adjustment arm.
Caution: While performing the
partial adjustment, it’s prohibited to
rotate the brake shoe support pin.
Caution: It’s prohibited to change
the travel of push rod by rotating the
push rod connecting fork of the
brake air chamber.
Caution: to adjust the rear brake,
park the vehicle at the flat ground
and make sure the air reservoir is at
700kPa or more.

Manual adjustment of
service brake (hydraulic
brake) (if equipped)
Check and adjust the brake clearance
during maintenances at interval of
10,000km.
Under normal condition, the
clearance between brake drum and
brake shoe friction plate shall be
0.20~0.30mm.
Adjustment method:
Elevate the wheel to be adjusted off
the ground by a jack.
Disassemble the rubber plug from
the adjustment hole on the brake
baseplate.
Insert a flat-end screwdriver into the
adjustment hole, shift the adjustment
piston towards the marking “+” on
the dust cover to open the brake shoe,
and rotate the wheel by hand, till the
Adjustment of vehicle
wheel can’t be rotated further. Caution: Never adjust the arm
Shift the adjustment piston in reverse manually; otherwise the transmission
mechanism may be damaged.
direction, namely the marking “--",
for 5~6 teeth, so that the wheel can Air bleeding of hydraulic
rotate flexibly. In such case, the
brake clearance is approximately brake system
0.25~0.30mm. Then, adjust the
adjustment piston of other brake
cylinder as per same method.
Install the rubber cap of adjustment
hole, lower the wheel, and take out
the jack.
Auto adjustment of
service brake (if
1. Observation hole plug
equipped) 2. Adjustment hole rubber plug
Apply grease during maintenance 3. Dust cap
every 20,000km.
If the hydraulic parts and pipelines
The auto adjusting arm keeps contain air, the depressing of brake
reasonable clearance between brake pedal can feel that the pedal travel is
drum and friction lining without increased with a higher depressing
manual adjustment. force, without the end feeling,
namely the pedal feels not hard. In
7-5
Adjustment of vehicle
such case, the air bleeding is
required for the hydraulic brake
system. Air bleeding method:
Top up the brake and clutch fluid
reservoir with 901-4 synthetic brake
fluid.
Disassemble the dust cap of brake
cylinder air bleeding bolt, loosen the
air bleeding bolt, attach one end of a
plastic pipe in same diameter with
bleeder port of air bleeding bolt onto
the air bleeding bolt, insert the other
end into a bottle filled with brake fluid,
and depress the brake pedal repeatedly
so that the air bubbles are bled from
the bottle. When there is no bleeding
of air bubble and the pedal force is
increased, tighten the air bleeding bolt
and remove the plastic pipe.
Caution: While tightening the air
bleeding bolt, do not apply excessive
force. It’s preferable to feel laborious
with hand. Excessive torque will
7-6
damage the sealing strip of air bleeding
bolt to cause oil leakage. While using a
plastic pipe to bleed the air, the
opening of the pipe end inserted into
the bottle filled with brake fluid shall
not be out of the fluid.
Adjustment of wheel hub
bearing
Adjustment of front wheel
hub bearing
1. Gasket 2. Wear retainer
3. Lock nut 4. Cotter pin
5. Wheel hub cover
1. Use the 120~150N⋅m to tighten
the lock nut 3 and at the same
time, rotate the wheel hub by 2-3
cycles to have it completely fit
with the bearing.
2. Use the 120~150N⋅m to tighten
the lock nut3 to have the bearing
positioned correctly.
3. Back the lock nut by 1/3 cycle. If
the cotter pin 4 slot cannot be
aligned, slightly screw off the
steering knuckle nuts until the it
is installed into the cotter pin 4.

Adjustment of rear wheel hub
bearing
1. Adjusting nut 2. Oil sealing housing
3. Outside seals of wheel hub
4. Lock washer 5. Lock nut
1. Use 150~180N ⋅ m torque to
tighten the wheel hub bearing nut,
meanwhile, rotate the wheel hub
to have the bearing roller at the
correct position.
2. Loosen the wheel hub bearing
nut by 1/6 cycle to have the
threaded hole of nut aligned with
the hole at the adjacent lock
Adjustment of vehicle
washer. Adjustment of the free
3. Tighten the positioning screw, travel of steering wheel
meanwhile, wheel could freely
rotate, without obviously axial Free travel
play or swing.
Caution: Smoothly and safely
remove and install the wheel hub for
maintenance to ensure the edge of oil
seals is not damaged.
Caution: Do not lose the out ring of
oil seal.
Caution: After removal of wheel Every 10000k m check the free
travel of steering wheel and the
hub, the oil seal should be replaced
timely, of which lip should be measured value should be equal to
applied with a little grease before less than 15 degree each at the left
setup. side and at the right side.
If the free travel is too excessive,
Caution: Within the initial 10Km
refer to the following steps for
after the wheel hub bearing is
inspection and adjustment:
adjusted, pay attention to the wheel
hub temperature. In case of it too hot, 1. Check whether the clearance of
it means the bearing is too tight, front wheel hub bearings is too
readjust it. wide, adjust it if needed.
2. Check whether the joint of
7-7
Adjustment of vehicle
steering tie-rod/drag link is loose,
if so, replace it.
3. Check whether the connection
between the steering pitman and
rocker of steering gear and bolts
are loose.
Front wheel toe-in
adjustment
Every 10000km, check and adjust
the front wheel toe-in. Improper
toe-in could seriously deteriorate the
front tires.
Toe-in adjustment of front wheel:
7-8
1. Park the vehicle on the flat Sideslip: 0~5mm/m
ground, jack up the front axle to
have the wheel at straightforward
traveling position, loosen the
bolts attached to the clamp of tie
rod. At last, use the pipe pliers to
rotate the tie rod to the needed
toe-in.
2. During adjustment, mark the mid
of tread pattern of left and right
tires. The measured value in the
right front of axle is marked as B
and then rotate the mark to the
dead rear and the measured value
is marked as A, at last, A-B=
toe-in;
3. After the proper adjustment,
tighten the bolts attached to the
clamp.
4. If needed, check the sideslip of
tires. Adjust the toe-in to have
the sideslip of tire meet the
stipulated requirements.
 Maintenance period and data

Maintenance period and data

Regular service table
User should refer to this chapter stipulated maintenance regulations and intervals for vehicle maintenance and service.
Running-in mileage: 1500～2500km.
The followings are the basic maintenance items and technical requirements of Dongfeng light-duty commercial vehicle.
Some items are needed to be further added in cased of failed parts.
Caution: the maintenance interval should be properly shortened at the severe working conditions, so as to make sure
your vehicle is reasonably serviced and improved in reliability. Never prolong the maintenance interval.
Table I: Running-in specifications
Area S/N Maintenance items Technical requirements
Check the lighting, signal, instruments and
1 Complete and effect
horns.
2 Check the glass and rearview mirror. There should be no scratch on the glass and mirror.
Cab Wiper could work normally at each gear. The washer could
3 Wiper and washer
work normally.
They should rotate smoothly and the seat belt could be
4 Check the door hinge, lifter and seat belt.
retracted normally.
Check sealing performance of radiator and Good opening valve performance, without water
Engine system 1
expansion tank cover leakage

8-1
Maintenance period and data
Area S/N Maintenance items Technical requirements
Within upper and lower markings of engine oil
2 Check the engine oil level and the leakage.
dipstick.
3 Check for fuel leakage. No leakage
4 Inspect and adjust valve clearance Adjust to specified value
Inspect tightening torque of cylinder head
5
bolts
Check the bolts of intake and exhaust
6 Tightened without looseness.
manifolds for tightness.
Check the oil pipeline, the coolant pump and
7 No leakage
the coolant pipe for leakage.
The deflection is 10~20mm under 20~40N applied
8 Check the fan belt for its proper tension.
force.
Use the designated products for applicable seasons and
9 Change engine oil. regions (Cummins engine is not required to be
replaced at first maintenance)
Before installation, fill the tank with clean lubricating
10 Replace the oil filter or filter element oil (Cummins engine is not required to be replaced at
first maintenance)
11 Check and clean air filter element 0.3Mpa compressed air blowing, light detection point
Chassis-drive and The clutch could work normally, with no joggling. For
1 Check the free travel of clutch.
brake system the free travel, refer to the manual.

8-2
 Maintenance period and data
Area S/N Maintenance items Technical requirements
Check the oil level in clutch oil reservoir The oil level should be equal to or higher than 2/3
2
and leakage. capacity, and there should be no leakage.
Check transmission oil level and add as
3 Use the oil grade suitable for the seasons and regions.
necessary.
There should be no looseness and wire, and the scale
4 Check the parking brake performance
marks are obvious.
The brake should be able to work smoothly and
5 Check the free travel of brake pedal.
effectively.
Check whether brake pipeline (liquid or air)
6 There should be no liquid or air leakage.
is leaked.
7 Check whether the steering gear is leaked. There should be no leakage, refill it if needed.
The rotating angle should be less than 15 degree. The
Check the steering wheel free travel and
8 steering wheel should be tight and able to rotate
operation conditions.
smoothly.
Check the steering gear and frame for
9 There should be no looseness, with reliable tightness.
tightness.
Check the steering arm, steering tie rod/drag
10 There should be no looseness, with reliable tightness.
link and pitman.
Check the steering linkage and joints for There should be no looseness, with reliable tightness.
11
tightness. The dust cover should be no damage.
Check whether the shock absorber is intact
12 There should be no oil leakage, looseness or damage.
and tight.

8-3
Maintenance period and data
Area S/N Maintenance items Technical requirements
At full load state, tighten the U bolts of front
13 There should be no looseness, damage or crack.
and rear leaf spring.
14 Check the leaf spring sleeve for wear. Replace it if needed.
15 Change the final drive lubricant. Use the stipulated oil: GL-5 gear oil.
16 Tighten the wheel bolts. Refer to the stipulated torque to crossly tighten them.
The tire surface should be free of crack and screw. The
17 Check the tires for wear. depth of tread pattern should not exceed the wear
mark.
18 Check the toe-in and steering angle. Check and adjust them to the stipulated requirements.
Check the bolts attached to the both ends of
19 There should be no looseness, with reliable tightness.
drive axle for tightness.
Check the nuts attached to the power
20 steering mechanism and oil outlet pipe There should be no looseness, with reliable tightness.
assembly for tightness.
Check and clean the power steering oil
Use the fluid grade in compliance with the stipulations
21 reservoir and the oil return filter element;
and suitable for the local temperature.
change the power steering fluid.
Check the frame, cab and latches of carriage
1 They should be not loosened.
Others for tightness.
2 Add the grease at each lubricating point. Refer to the manual for requirements.

8-4
 Maintenance period and data
Area S/N Maintenance items Technical requirements
Check the battery appearance and “electric
3 Normal display
eye”

Table II: Maintenance specifications every 5000km

Area S/N Maintenance items Technical requirements
Check the lighting, signal, instruments and
1 Complete and effect
horns.
2 Check the glass and rearview mirror. There should be no scratch on the glass and mirror.
Cab Wiper could work normally at each gear. The washer
3 Wiper and washer
could work normally.
They should rotate smoothly and the seat belt could be
4 Check the door hinge, lifter and seat belt.
retracted normally.
Check sealing performance of radiator and
1 Tightened without looseness.
expansion tank cover
Inspect tightening torque of cylinder head
2
bolts
Engine and system
Check the bolts of intake and exhaust
3 No leakage
manifolds for tightness.
Check the oil pipeline, the coolant pump Oil amount between the upper and lower scale marks is
4
and the coolant pipe for leakage. about 2.5L

8-5
Maintenance period and data
Area S/N Maintenance items Technical requirements
Check all portions for normal status, check
5 accessories for reliable connections, and
check pipelines for damage and wear
6 Check fuel and cooling liquid for leakage
The deflection is 10~20mm under 20~40N applied
7 Check the engine oil level and the leakage.
force.
Check electronic system harness for outer
8
skin damage and wire nail for looseness
9 Check the wearing of belt Technical requirements
Check if the tensioner and rotation of idler
10
are normal.
Check and tighten connecting bolts and
11 nuts of intake and exhaust system and
check for good sealing gaskets
The clutch could work normally, with no joggling. For
1 Check the free travel of clutch.
the free travel, refer to the manual.
Chassis /drive /brake The oil level should be equal to or higher than 2/3
2 Check the clutch oil reservoir and leakage.
/steering system capacity, and there should be no leakage.
Check the gearbox oil level and check for
3 Add it if needed.
the leakage.

8-6
 Maintenance period and data
Area S/N Maintenance items Technical requirements
There should be no looseness and wire, and the scale
4 Check the parking brake performance
marks are obvious.
The brake should be able to work smoothly and
5 Check the free travel of brake pedal.
effectively.
Check whether brake pipeline (liquid or
6 There should be no liquid or air leakage.
air) is leaked.
7 Check whether the steering gear is leaked. There should be no leakage, refill it if needed.
The rotating angle should be less than 15 degree. The
Check the steering wheel free travel and
8 steering wheel should be tight and able to rotate
operation conditions.
smoothly.
Check the steering gear and frame for
9 There should be no looseness, with reliable tightness.
tightness.
Check the steering arm, steering tie
10 There should be no looseness, with reliable tightness.
rod/drag link and pitman.
Check the steering linkage and joints for There should be no looseness, with reliable tightness.
11
tightness. The dust cover should be no damage.
Check whether the shock absorber is intact
12 There should be no oil leakage, looseness or damage.
and tight.
At full load state, tighten the U bolts of
13 There should be no looseness, damage or crack.
front and rear leaf spring.
14 Check the leaf spring sleeve for wear. Replace it if needed.

8-7
Maintenance period and data
Area S/N Maintenance items Technical requirements
Check the final drive oil level and check
15 Add it if needed.
for the leakage.
16 Tighten the wheel bolts. Refer to the stipulated torque to crossly tighten them.
The tire surface should be free of crack and screw. The
17 Check the tires for wear.
depth of tread pattern should not exceed the wear mark.
18 Check the toe-in and steering angle. Check and adjust them to the stipulated requirements.
Check the bolts attached to the both ends of
19 There should be no looseness, with reliable tightness.
drive axle for tightness.
Check the connection nut attached to inlet
20 and outlet pipe assembly of power steering There should be no looseness, with reliable tightness.
gear for tightness.
Check the frame, cab and latches of
1 They should be not loosened.
carriage for tightness.
The steering knuckle kingpin and drag
It is regarded as being filled up when extruded out by
2 link/tie rod ball pin should be filled with
used oil
Others the greased.
The drive shaft sliding fork and the cross It is regarded as being filled up when extruded out by
3
bearing should be filled with the grease used oil
Check the appearance of battery and
4 It should display normally.
“electricity eye”

8-8
 Maintenance period and data

Table III: Maintenance specifications every 10000km

Area S/N Maintenance items Technical requirements
1 Check the lighting, signal, instruments and horns. Complete and effect
2 Check the glass and rearview mirror. There should be no scratch on the glass and mirror.

Cab Wiper could work normally at each gear. The washer

3 Wiper and washer
could work normally.
They should rotate smoothly and the seat belt could be
4 Check the door hinge, lifter and seat belt.
retracted normally.
Check sealing performance of radiator and expansion
1 Good opening valve performance, without water leakage
tank cover
2 Inspect tightening torque of cylinder head bolts

3 Inspect and adjust valve clearance Adjust to specified value

Engine and Check the bolts of intake and exhaust manifolds for
4 Tightened without looseness.
system tightness.
Check the oil pipeline, the coolant pump and the
5 No leakage
coolant pipe for leakage.
Check all portions for normal status, check
6 accessories for reliable connections, and check
pipelines for damage and wear
7 Check fuel and cooling liquid for leakage

8-9
Maintenance period and data
Area S/N Maintenance items Technical requirements
Oil amount between the upper and lower scale marks is
8 Check the engine oil level and the leakage.
about 2.5L
Engine and
system Check electronic system harness for outer skin
9
damage and wire nail for looseness
The deflection is 10~20mm under 20~40N applied
10 Check the wearing of belt
force.
Check if the tensioner and rotation of idler are
11
normal.
Check and tighten connecting bolts and nuts of
12 intake and exhaust system and check for good
sealing gaskets

13 Change engine oil; 0.3Mpa compressed air blowing, light detection point

14 Replace the oil filter or filter element and seal ring Water draining and sediment removal
15 Replace fuel filter (for D28 engine) Drain, discharge accumulated matter
Drain, discharge accumulated matter, Replace it at every
Check fuel filter (for ZD30 engine)
40,000 km
Replace fuel-water separator assembly (for D28
16
engine)

17 Check and clean air filter element Replace filter element at every 20,000 km

8-10
 Maintenance period and data
Area S/N Maintenance items Technical requirements
18 Check and adjust the valve lash Check at every 20,000km

19 Check the working condition of supercharger Check at every 20,000km

20 Check shock absorber appearance Check at every 20,000km

21 Change fuel hose Every 4 years or every 120,000km

The clutch could work normally, with no joggling. For
1 Check the free travel of clutch.
the free travel, refer to the manual.
2 Check the clutch oil reservoir and leakage. There should be sufficient oil and no leakage.
Use the stipulated Dongfeng oil grade, and change it
3 Check the transmission oil level, refill it if needed.
every 20000km.
There should be no looseness and wire, and the scale
4 Check the parking brake performance
marks are obvious.
The brake should be able to work smoothly and
Chassis /drive 5 Check the free travel of brake pedal.
effectively.
/brake /steering
system Check whether brake pipeline (liquid or air) is
There should be no liquid or air leakage.
6 leaked.
Change brake fluid Every 2 years or every 40,000km
7 Check whether the steering gear is leaked. There should be no leakage, refill it if needed.

8-11
Maintenance period and data
Area S/N Maintenance items Technical requirements
The rotating angle should be less than 15 degree. The
Check the steering wheel free travel and operation
8 steering wheel should be tight and able to rotate
conditions.
smoothly.
9 Check the steering gear and frame for tightness. There should be no looseness, with reliable tightness.
Check the steering arm, steering tie rod/drag link and
10 There should be no looseness, with reliable tightness.
pitman.
Chassis /drive There should be no looseness, with reliable tightness.
/brake /steering 11 Check the steering linkage and joints for tightness.
The dust cover should be no damage.
system
Inspect and clean the screen of power steering oil
12 Change the power steering oil every 20000km.
tank.
13 Check whether the shock absorber is intact and tight. There should be no oil leakage, looseness or damage.
At full load state, tighten the U bolts of front and rear
14 There should be no looseness, damage or crack.
leaf spring.
15 Check the leaf spring sleeve for wear. Replace it if needed.
Check whether the final drive for oil leakage and oil There should be no oil leakage, refill it if needed.
16
level. Change the oil every 20000km.
The nuts attached to the front/rear wheel hub bearings
Remove the front and rear wheel bearings and fill the
17 should be torqued to the 160~190N.m. For more
grease (four-wheel maintenance.)
information, refer to the manual.
Tighten the brake base and check the brake
18 Check and adjust the braking clearance to specifications.
clearance.

8-12
 Maintenance period and data
Area S/N Maintenance items Technical requirements
The shoes wear should not exceed the plane of recessed
19 Check the brake shoes and brake drum for wear.
rivets. Remove the non-rounded brake drum.
20 Tighten the wheel bolts. Refer to the stipulated torque to crossly tighten them.
The tire surface should be free of crack and screw. The
21 If needed, exchange the tires.
depth of tread pattern should not exceed the wear mark.
22 Check the toe-in and steering angle. Check and adjust them to the stipulated requirements.
Check the bolts attached to the both ends of drive
23 There should be no looseness, with reliable tightness.
axle for tightness.
Check the nuts attached to the power steering
24 mechanism and oil outlet pipe assembly for There should be no looseness, with reliable tightness.
tightness.
Check the frame, cab and latches of carriage for
1 They should be not loosened.
tightness.
Others 2 Add the grease at each lubricating point. Refer to the manual for requirements.
Check the battery appearance, “electric eye” and
3 Charge it if needed
“electricity”

Table IV: Mandatory Maintenance Items of Cummins Engine (I) (EURO II/III/IV)
Maintenance item at interval of Maintenance item at interval of
Maintenance Items Daily inspection
10,000km 20,000km
Replace lubricating oil
Parts to be replaced
Replace engine oil filter

8-13
Maintenance period and data
Replace coolant filter Replace coolant filter
Replace fuel filter Replace fuel filter
Replace steering hydraulic oil
Lubricating oil level Check air filter Check air filter
Coolant level Check intake system Check intake system
Drive belt and fan Check inter-cooler Check inter-cooler
Water drainage from
Check anti-rust antifreeze
fuel-water separator
Checking of oil leakage for air
Inspection items Check air compressor lock bolts and Check air compressor lock bolts and
compressor lock bolts and
nuts and brake system for leakage nuts and brake system for leakage
nuts and brake system
Intake pipe
Air reservoir and fluid Battery and battery cables and
reservoir (if equipped) connectors
Daily checking of urea level
(if equipped)
Inspection or adjustment Valve clearance Valve clearance

Mandatory Maintenance Items of Cummins Engine (II) (EURO II/III/IV)

Maintenance item at interval of Maintenance item at interval of Maintenance item at interval of
Maintenance Items
30,000km 40,000km 50,000km
Replace lubricating oil
Parts to be replaced
Replace engine oil filter

8-14
 Maintenance period and data
Replace coolant filter Replace coolant filter Replace coolant filter
Replace fuel filter Replace antifreeze
Replace steering hydraulic oil
Check air filter Check air filter Check air filter
Check intake system Check intake system Check intake system
Check inter-cooler Check inter-cooler Check inter-cooler
Check anti-rust antifreeze
Check air compressor lock bolts Check air compressor lock bolts
and nuts and brake system for Check fan shaft and bolts and nuts and brake system for
Inspection items leakage leakage
Check and tighten cylinder head
Check belt tensioner and belt tension
bolts
Battery and battery cables and
connectors
Check air compressor lock bolts and
nuts and brake system for leakage
Inspection or
Valve clearance Valve clearance
adjustment

Mandatory Maintenance Items of Cummins Engine (III) (EURO II/III/IV)

Maintenance Maintenance item at interval of Maintenance item at interval
Maintenance item at interval of 80,000km
Items 60,000km of 70,000km
Parts to be Replace lubricating oil Replace lubricating oil

8-15
Maintenance period and data
Maintenance Maintenance item at interval of
Items 60,000km
replaced Replace engine oil filter
Replace coolant filter
Replace fuel filter
Replace thermostat
Replace steering hydraulic oil
Check air filter
Check intake system
Check inter-cooler
Check anti-rust antifreeze
Check air compressor lock bolts and
Inspection items
nuts and brake system for leakage
Battery and battery cables and
connectors
Inspection or
Valve clearance
adjustment
8-16
Maintenance item at interval
of 70,000km
Replace coolant filter
Check air filter
Check intake system
Check inter-cooler
Check air compressor lock bolts
and nuts and brake system for Check fan shaft and bolts
leakage
Valve clearance
Maintenance item at interval of 80,000km
Replace engine oil filter
Replace coolant filter
Replace fuel filter
Replace fuel strainer
Replace steering hydraulic oil
Check air filter
Check intake system
Check inter-cooler
Check anti-rust antifreeze
Check belt tensioner and belt tension
Battery and battery cables and connectors
Check air compressor lock bolts and nuts and
brake system for leakage
Valve clearance
 Maintenance period and data
Mandatory Maintenance Items of Cummins Engine (IV) (EURO II/III/IV)
Maintenance Items Maintenance item at interval of 90,000km Maintenance item at interval of 100,000km
Replace lubricating oil
Replace engine oil filter
Replace coolant filter Replace coolant filter
Replace fuel filter
Replace antifreeze
Replace steering hydraulic oil
Check air filter Check air filter
Check intake system Check intake system
Parts to be replaced Check inter-cooler Check inter-cooler
Check anti-rust antifreeze
Check air compressor lock bolts and nuts and brake Check air compressor lock bolts and nuts and
system for leakage brake system for leakage
Check and tighten cylinder head bolts
Battery and battery cables and connectors
Check shock absorber
Radiator hose
Steam cleaning of engine

8-17
Maintenance period and data
Maintenance Items Maintenance item at interval of 90,000km Maintenance item at interval of 100,000km
Air compressor exhaust hose
Valve clearance Valve clearance
Engine brake assembly (if equipped)

Caution: when the 100thousand kilometer items are completed, begin the cycle with 50thousand kilometers until the
end of warranty period. It is hopped that the users could refer to the related contents for engine maintenance even
though the warranty is expired.

8-18
 Maintenance period and data
Table V: Mandatory Maintenance Items of Cummins Engine (I) (EURO V)
Maintenance items of every 10,000 Maintenance items of every 20,000
Maintenance
Daily inspection km, every 250 hours or every 3 km, every 500 hours or every 6
item
months months

Replacement Drain off fuel-water separator Fuel filter (spin-on)

item Oil and filter
Air pipe of crank case Air intercooler Cooling system
Check if the radiator pressure cover can
Oil level Resistance of air filter
be used
Driving belt and fan Air compressor
Coolant level
Checking item
Check lock nuts and bolts of air
compressor and brake system for
fuel leak
Intake pipe
Level of DEF
Check or adjust

8-19
Maintenance period and data
Compulsory maintenance items of Cummins engine (II) (EURO V)
Maintenance items of every
Maintenance item 40,000 km, every 1,000 hours
or every 1 year
Replacement item
Check if it is ok to drive the fan
hub with fan belt
Maintenance items of every 60,000
km, every 1,500 hours or every 1
year
Post-treatment DEF air/water separator
Maintenance items of every 80,000 km,
every 2,000 hours or every 2 years
Cooling system – flushing (change the
coolant)

Checking item Radiator hose

Cooling fan belt tensioner
Air compressor vent hose
Check or adjust

Compulsory maintenance items of Cummins engine (III) (EURO V)

Maintenance item Maintenance items of every 120,000km or every Maintenance items of every 240,000km, 5,000 hours or
2,500 hours every 4 years
Post-treatment DEF—injection unit filter
Replacement item
Post-treatment DEF—tank filter
Check or adjust Overhead mechanism setting

Note: The maintenance shall be based on interval whichever comes first and perform the maintenance items.

8-20
 Maintenance period and data
Maintenance mileage of Cummins EURO VI engines

Maintenance scheme I Maintenance scheme II

Applicable
Oil sump
Engine model operation Remarks
configuration Engine oil Maintenance Engine oil Maintenance
conditions
model mileage model mileage

40.000
20.000km/ 6
Trucks Kilometer/ 1
months
Year For
sanitation
20.000 10.000 vehicles,
Sanitation CK-4(10W40) Kilometer/1 CJ-4(15W40) Kilometer/6 special
CES20086 Year CES20081 months vehicles and
under
D4.0 CM2620 D103B 14L Sanitation severe
30.000 1.50.000
(average conditions,
Kilometer/1 Kilometer/6
vehicle speed the
Year months
≥20km/h) maintenance
mileage
Sanitation shall be
10.000 halved.
(average
Kilometer/6 5000Km/3months
vehicle speed＜
months
20km/h)

Maintenance items of Cummins EURI VI engines

Compulsory maintenance process and requirements

8-21
Maintenance period and data
The mandatory maintenance period in the following table shall be observed within the quality warranty. For the detailed
maintenance items and periods, see below: In the table, “●” means the inspection items to be implemented within the
corresponding period (mileage or months, whichever comes firstly); for example “air filter resistance” shall be checked
every 20000km or every 6 months and the overhead mechanism (valve clearance) every 80000km or 24 months until
the quality warranty period is expired. Which could be also referred to for the maintenance of engine even after the
warranty is expired.
Mandatory maintenance schedule for D4.0 CM2620 D103B engines
Traveling mileage
20 40 100 120 160 300
Maintenance items (×1000km)
Time (Month) 6 12 24 24 24 36
Resistance of air filter ●
Air-to-air intercooler pipeline ●
Air-to-air intercooler ●
Battery ●

Checking Battery cable and joint ●

item Air compressor ●
Cooling System ●
Belt-driving fan hub ●
Cooling fan belt tensioner ●
Pressure cap of radiator ●

8-22
 Maintenance period and data
Traveling mileage
20 40 100 120 160 300
Maintenance items (×1000km)
Time (Month) 6 12 24 24 24 36
Air compressor vent hose ●
Radiator hose ●
Overhead mechanism (valve clearance) ●
Aftertreatment diesel particulate filter (DPF) ●
Engine oil
Refer to the steps of “Maintenance Schedule of Engine Oil and Filter”
Engine oil filter
Replacement Fuel filter (spin-on type) Replacement with engine oil and its filter
item
Filter of diesel exhaust fluid tank of
●
aftertreatment
Post-treatment DEF—injection unit filter ●

Maintenance schedule of engine oil and filter

Replacement interval of engine oil: Under severe working conditions, the maintenance interval shall be shortened.
Definition of work load cycle: Heavy-duty work load cycle: idling duration accounts for 40%, fuel consumption higher
than 21L/100km and total mass ＞18t; normal work load cycle: idling duration less than 40%, fuel consumption lower
than 21L/100km and total mass ≤18t.

8-23
Maintenance period and data
Engine oil change interval for trucks, coaches and transfer carts

Added engine oil Work load cycle Kilometer Mile Hours Month

Normal 40000 25000 - 12

Only the fuel with max.10ppm of sulfur content and meeting API
CK-4(CES 20086).
Heavy load 20000 12500 - 6

Normal 20000 12500 - 6

Only the fuel with max.10ppm of sulfur content and meeting API
CJ-4(CES 20081).
Heavy load 10000 6250 - 3

Engine oil change interval of sanitation vehicles

Used engine oil/fuel Kilometer Mile Hours Month

Only the fuel with max.10ppm of sulfur content and meeting API CK-4 (CES 20086) 20000 12500 1000 12

Only the fuel with max.10ppm of sulfur content and meeting API CJ-4 (CES 20081) 10000 6250 500 6

Caution: For sanitation vehicles, special vehicles and under severe conditions, the initial and periodic maintenance
mileages shall be halved.
Caution: The maintenance mileage and interval shall be properly shortened as the case may be.
Caution: If the max. sulfur content in the fuel exceeds 10ppm, the replacement interval shall be shortened by 50%.
Caution: Options of DPF maintenance intervals: prolong the maintenance interval - maintenance indicator and DPF
8-24
 Maintenance period and data
maintenance fault code will show the DPF is full of dust. DPF maintenance code such as the ash
accumulation may vary with the changing work load cycle. In order to reduce the maintenance cost, it is
recommended to use the maintenance indicator as the DPF maintenance indicator. With the maintenance
indicator in working, it is normal that the maintenance interval goes beyond the requirements in the table. The
DPF shall be maintained more frequency if the added engine oil does not meet (API) CJ-4 or above, if the
engine brake is applied frequently or for a long time, or if the engine idles for a long time. Aftertreatment of
diesel engine particulate filter DPF ash load percentage - data is valid, but higher than normal work range -
min. severity level, engine fault code: 5383, and the aftertreatment DPF needs to be cleaned or replaced.
Table VI: Compulsory maintenance items of ZD30/D28 engine(EURO V and below EURO V)
Maintenance items Maintenance items
Maintenance items
every 10000km (carry every 20000km (carry
every 5000km (carry
Maintenance Inspection items Daily out the following items, out the following items,
out the following items,
item for new engines Maintenance in addition to the in addition to the
in addition to the daily
5000km maintenance 10000km maintenance
maintenance)
items) items)
Replace air filter
Replace the engine oil.
element.
Replace the engine oil
Replacement filter and the seals.
item Replace the fuel-water
separator.
Replace the fuel filter
assembly.

8-25
Maintenance period and data
Maintenance items Maintenance items
Maintenance items
every 10000km (carry every 20000km (carry
every 5000km (carry
Maintenance Inspection items Daily out the following items, out the following items,
out the following items,
item for new engines Maintenance in addition to the in addition to the
in addition to the daily
5000km maintenance 10000km maintenance
maintenance)
items) items)
Check all portions
for normal status,
check accessories Check electronic system
Check for leakage of
for reliable harness for outer skin Check and adjust the
engine oil, fuel, and Check air filter assembly.
connections, and damage and wire nail for valve lash
coolant.
check pipelines looseness
for damage and
wear

Check high and low

Checking item pressure fuel pipes
for presence of Check the engine Check the working
Check the wearing of
squeezing, friction, oil level and the condition of
belt
and knocking leakage. supercharger
scratches with other
parts.

Check the harness and

Check if the tensioner
connection of sensor Check for fuel Inspect the shock
and rotation of idler are
and mechanical leakage. absorber appearance
normal.
connection

8-26
 Maintenance period and data
Maintenance items Maintenance items
Maintenance items
every 10000km (carry every 20000km (carry
every 5000km (carry
Maintenance Inspection items Daily out the following items, out the following items,
out the following items,
item for new engines Maintenance in addition to the in addition to the
in addition to the daily
5000km maintenance 10000km maintenance
maintenance)
items) items)
Check and fasten the
connection bolt and nut
Check all cushions Check for leakage
of air intake and exhaust
for presence of tear. of coolant.
system and check if the
seal liner is intact.

Check the engine for

presence of
abnormal sound.

Performed by special service personnel of Customer

The user can fulfill by self as per the operation practices.
Service Center of Dongfeng Light Engine Co., Ltd

8-27
Maintenance period and data
Mandatory maintenance items for ZD30 EURO VI engines

Maintenance items Maintenance items Maintenance items

Maintenance items
every 10000km (carry every 20000km (carry every 40000km (carry
Checking every 5000km (carry
Maintenance Daily First maintenance items out the following items, out the following items, out the following items,
Items of New out the following items,
Items Maintenance (5000km/ 6 months) in addition to the in addition to the in addition to the
Engine in addition to the daily
5000km maintenance 5000km maintenance 20000km maintenance
maintenance)
items) items) items)

Replace the filter

Replace the oil-water
Replace the engine oil. Replace the engine oil. element of Adblue
separator element.
pump assembly.

Replace the engine oil Replace the engine oil

Replacement of fuel
Replacement filter element and seal filter element and seal
filter element
item ring. ring.

Replace the oil-water Replace air filter

separator element. element.

Check various
parts for
Check for
normality, Check electronic
leakage of Check the filter
Checking attachment system harness for
engine oil, Check the fuel filter. element of Adblue
item connection for outer skin damage and
fuel, and pump assembly
reliability, and wire nail for looseness
coolant.
all pipes for
damage or wear

8-28
 Maintenance period and data

Maintenance items Maintenance items Maintenance items

Maintenance items
every 10000km (carry every 20000km (carry every 40000km (carry
Checking every 5000km (carry
Maintenance Daily First maintenance items out the following items, out the following items, out the following items,
Items of New out the following items,
Items Maintenance (5000km/ 6 months) in addition to the in addition to the in addition to the
Engine in addition to the daily
5000km maintenance 5000km maintenance 20000km maintenance
maintenance)
items) items) items)

Check high
and low
pressure fuel
pipes for Check engine Check if the air filter
presence of oil level and Check the wearing of assembly is clean and Check and adjust the
squeezing, check for belt blow its element if valve lash
friction, and leakage needed.
knocking
scratches with
other parts.

Check the
harness and
Check fuel Check if the tensioner Check the working
connection of
leakage and rotation of idler are condition of
sensor and
condition normal. supercharger
mechanical
connection

Check and fasten the

Check all
connection bolt and nut
mechanical Check for
of air intake and Check appearance of
connections for leakage of
exhaust system and shock absorbers
presence of coolant.
check if the seal liner is
looseness
intact.

8-29
Maintenance period and data
Maintenance items Maintenance items Maintenance items
Maintenance items
every 10000km (carry every 20000km (carry every 40000km (carry
Checking every 5000km (carry
Maintenance Daily First maintenance items out the following items, out the following items, out the following items,
Items of New out the following items,
Items Maintenance (5000km/ 6 months) in addition to the in addition to the in addition to the
Engine in addition to the daily
5000km maintenance 5000km maintenance 20000km maintenance
maintenance)
items) items) items)

Check all Check the air filter

cushions for assembly and purge the
presence of filter element (ZD30
tear. China-VI)

Check the
engine for
Checking
presence of
item
abnormal
sound.

Performed by the special-authorized service stations of DFAC or the professional servicemen of

The user can fulfill by self as per the operation practices.
DFLE Service Center.

Cuation: Initial maintenance items shall be performed at the initial 5000km, and then daily, every 5000km, 10000km,
20000km and 40000km.
Engine of Liuzhou Automobile
Running-in specification of gasoline engine
As the initial service status of gasoline engine has great effect on its service life, its running-in must be carried out
according to the following table for 1000km before the normal use, which shows the running-in specifications of new
gasoline engine:

8-30
 Maintenance period and data

Transmission gear Gear - I Gear - II Gear - III Gear - IV Gear - Ⅴ

Maximum speed
20 35 50 70 90
(km/h)

The following rules shall be observed during the running-in:

1. After startup, don’t run the engine at high speed, but slowly warm it up and drive away. Besides, it is prohibited to
accelerate it sharply.
2. Don’t run at a speed unchanged for a long time, as the continuous changing of vehicle speed could run the moving
parts very well.
3. In the first 320km, avoid the sudden braking.
4. Vehicle should run at the proper speed, and don’t run at slow speed with the transmission at the low-speed gear.
5. In the first 1000km, don’t tow any other vehicles.
6. Avoid running on the muddy, sandy, steep or other poor roads.
Maintenance Period and Contents
• Maintenance period of gasoline engine under the normal service conditions (The service period refers to the
mileage or months, whichever comes first.):
Kilometer
S/N 10 20 30 40 50 60 70 80
Location ×1000
.
Months 6 12 18 24 30 36 42 48
8-31
Maintenance period and data
1 Water pump belt - J.T.G - G - J.T.G - G
2 Engine oil filter Same as that of engine oil
Initial maintenance: 3000km or 45 days; then, change it every 5000km or
3 Engine oil
six months.
4 Gasoline engine coolant Filled if needed.
Hose and joint of
5 cooling system (liquid - J.T.G - J.T.G - J.T.G - J.T.G
leakage and damage)
Exhaust system (except
6 for the three-way - J.T.G - J.T.G - J.T.G - J.T.G
catalytic converter)
Ignition coil (damage,
7 deformation - J.T.G - J.T.G - J.T.G - J.T.G
deterioration)
8 Spark plug G G G G G G G G
9 Ignition timing J.T J.T J.T J.T J.T J.T J.T J.T
Cement or asphalt roads: clean it every 5000km and replace the filter seal if
10 Air filter needed; sandy and gravel roads: clean it every 2500km and replace the
filter seal if needed.
Fuel tank, fuel pipe, joint
11 J.T.G - - J.T.G - - - J.T.G
and pipe clamp

8-32
 Maintenance period and data
12 Fuel filter G G G G G G G G
Bleeder hose and joint of
13 - J.T.G - J.T.G - J.T.G - J.T.G
crankcase
14 Clutch J.T J.T J.T J.T J.T J.T J.T J.T
Initial maintenance: 3000km or 45 days; then, change it every 40000km or
15 Transmission oil
24 months.
Note: in the table, “G” means the replacement, “X” the rotation to the set torque, “J” the inspection and “T” the
adjustment
• Maintenance period under the severe conditions Number of severe status
A- Repeated driving for a short distance
B- Running on bumpy and muddy roads
C- Running on heavy dusty roads
D- Driving on salty roads in the very cold weather E-Repeated driving for a short distance in the very cold weather
Number of severe status Maintenance Maintenance operations Maintenance period
B, C Water pump belt J.T.G Every 10000Km or 12 months
A, C, D, E Engine oil and its filter G Every 5000Km or 6 months
A, B, D Exhaust pipe and its accessories J.T.G Every 10000Km or 12 months
C Air filter element J.T.G Every 3000Km or 3 months
A, B, C, E Plug G Every 5000Km or 6 months

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Maintenance period and data
B, E Manual transmission and nuts G Every 20000Km or 24 months
Note; in the table, “G” means the replacement, “J” the inspection and “T” the adjustment.
Compulsory maintenance for Yuchai engine
Initial maintenance
Maintenance Daily Level I maintenance Level II maintenance Level III maintenance
(running-in mileage
Items maintenance (15,000Km or 250h) (30,000Km or 500h) (60,000Km or 1,000h)
maintenance)
Change engine oil Change engine oil Change engine oil Change engine oil
Replace engine oil Replace engine oil Replace engine oil Replace engine oil
filter element filter element filter element filter element
Replace whole air Replace whole air
filter element filter element
Replacement
item Replace fuel filter Replace fuel filter
element (including element (including
fuel-water separator fuel-water separator
and fine filter) and fine filter)
Check and clean the air filter element (once maintenance every 5000km; after maintenance for six times, entire filter
element must be replaced. For more, refer to the air filter manual)
Check engine
Check engine for Check engine for Check engine for Check engine for
for leakage of
leakage of water, oil, leakage of water, oil, leakage of water, oil, leakage of water, oil,
water, oil, and
Checking and gas and gas and gas and gas
gas
item
Check fuel
Check fuel level in Check fuel level in Check fuel level in Check fuel level in
level in fuel
fuel tank fuel tank fuel tank fuel tank
tank

8-34
 Maintenance period and data
Initial maintenance
Maintenance Daily Level I maintenance Level II maintenance Level III maintenance
(running-in mileage
Items maintenance (15,000Km or 250h) (30,000Km or 500h) (60,000Km or 1,000h)
maintenance)
Check engine
Check engine oil Check engine oil Check engine oil Check engine oil
oil status and
status and level status and level status and level status and level
level
Check acceleration Check acceleration Check acceleration Check acceleration
and deceleration and deceleration and deceleration and deceleration
performances and performances and performances and performances and
exhaust status exhaust status exhaust status exhaust status
Check the Check the coolant Check the coolant Check the coolant Check the coolant
coolant level. level. level. level. level.
Check all connecting Check all connecting Check all connecting
points of electric points of electric points of electric
circuits for contact circuits for contact circuits for contact
status, interference, status, interference, status, interference,
and wear and wear and wear
Check fuel supply Check fuel supply
advance angle (for advance angle (for
mechanical inline mechanical inline
pump engine) pump engine)

8-35
Maintenance period and data
Initial maintenance
Maintenance Daily Level I maintenance Level II maintenance Level III maintenance
(running-in mileage
Items maintenance (15,000Km or 250h) (30,000Km or 500h) (60,000Km or 1,000h)
maintenance)
Check if the
supercharger works
normally (if the
impeller rotates
smoothly or if the
axial play is less than
1mm )
Clean appearance of Clean appearance of Clean appearance of
engine assembly engine assembly engine assembly
Drain water
Drain water from Drain water from Drain water from Drain water from
from fuel-water
fuel-water separator fuel-water separator fuel-water separator fuel-water separator
separator
Check or Check and adjust the Check and adjust the Check and adjust the Check and adjust the
adjust belt tension belt tension belt tension belt tension
Add lubricating grease Add lubricating grease
to water pump to water pump
(applicable for water (applicable for water
pump with lubricate pump with lubricate
oil nozzle structure) oil nozzle structure)
Clean engine cooling
system

8-36
 Maintenance period and data
Parts to be periodically replaced
The parts to be periodically replaced refers to the parts must be aging as the time passes by. Generally at periodically
maintenance, these parts cannot guarantee the traveling safety. Therefore, the reliable parts should be used to give the
traveling safety.
Date of change (year):
Parts to be replaced
1 2 3 4 5 6 7 8 9 10
All kinds of valves and rubber parts from the brake
★ ★ ★ ★ ★ ★ ★ ★ ★ ★
system
Each rubber hose of brake system ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Rubber hose for vacuum pump (hydraulic type) ★ ★ ★ ★ ★
Rubber hose for clutch control system (hydraulic type) ★ ★ ★ ★ ★
Rubber sealing ring of clutch master cylinder and salve
★ ★ ★ ★ ★
cylinder (hydraulic type)
Cross shaft assembly of drive shaft ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Joint pin assembly of cross shaft of steering drive shaft ★ ★ ★ ★ ★ ★ ★ ★ ★ ★

Main adjustment data

engine
Adjustment items Standard

8-37
Maintenance period and data
Liuzhou Automible
Engine model D28/ZD30 EQB ISD ISB3.8
LJ4A15Q
Intake valve
0.35±0.05 0.25±0.05 0.18~0.26 0.18~0.26 0.330
Valve clearance (mm)
(cold state) Exhaust
valve (mm)
0.35±0.05 0.5±0.05 0.26~0.34 0.26~0.34 0.584

Cab and chassis

Adjustment items Standard

The free travel of clutch pedal ≤40mm

Free rotation angle of steering wheel No more than ±15°

Clearance between the front and rear brake shoes and the brake 0.7mm (air brake)
drum 0.25~0.30mm (hydraulic braking)

Forward-backward adjustment of steering wheel ±7.5°

Up-down adjustment of steering wheel 30mm

Fuel
Gasoline engine
It is best to use the gasoline meeting GB17930-2016 92# or above, which is beneficial to keep the reliability of gasoline
engine.

8-38
 Maintenance period and data
Caution: Vehicle must use the qualified unleaded gasoline; otherwise, gasoline management system and three-way
catalyst converter will be damaged severely, and the environmental-protection performance will also drop.
Diesel engine(EURO V)
The user may choose different light diesel trademark depending on the ambient temperature in local region.
Caution: The diesel quality is of great influence on the emission of diesel engines. Only the diesel conforming to
standard can ensure the qualified gas and particulate emissions of the diesel engines.
Caution: use of the light fuel reduces the fuel economy or damages to the fuel injection pump.
Recommended temperature range:
Model: Application range
10# light diesel Suitable for the diesel engine with pre-heater
5# light diesel Suitable for the risk rate of 10%, min. temperature of 8 ℃ or more.
0# light diesel Suitable for the risk rate of 10%, min. temperature of 4 ℃ or more.
-10# light diesel Suitable for the risk rate of 10%, min. temperature of -5 ℃ or more.
-20# light diesel Suitable for the risk rate of 10%, min. temperature of -14 ℃ or more.
-35# light diesel Suitable for the risk rate of 10%, min. temperature of -29 ℃ or more.
-50# light diesel Suitable for the risk rate of 10%, min. temperature of -44 ℃ or more.

Diesel engine(EURO VI)

The vehicle China-VI diesels meeting GB19147-2016 shall be selected in the following table according to the ambient

8-39
Maintenance period and data
temperature.

Environment temperature Diesel trademark Environment temperature Diesel trademark

Above 4ºC 0# diesel for vehicles Above -29°C -35# diesel for vehicles

Above -5ºC -10# diesel for vehicles Above -44°C -50# diesel for vehicles

Above -14°C -20# diesel for vehicles

Caution: At relatively low ambient temperature, any diesel with incorrect grade must not be used; otherwise the wax
will be precipitated from the diesel, causing the diesel pipeline unsmooth or even blocking it. In such case,
the engine is difficult to start or is shut down.
Caution: In order to reduce faults and prolong the engine service life, the principle of “Clean Fuel” should be obeyed
always, for inferior diesel will significantly impair the fuel system from working normally, resulting in great
losses.
Parts to be greased and intervals
Each part of vehicle should be periodically greased.
Before adding the grease, clean the grease nozzle and parts to be lubricated.
After greasing, wipe the residuals. Cap the nozzle.
The following table is for initial 50000km lubrication, after that, refer to the interval in this table for lubrication.

8-40
 Maintenance period and data
☆—means the lubrication and maintenance items during running-in of 1500~2500km
★—means the lubrication items during normal travel.
Lubrication intervals (× 1000km)
Parts to be lubricated
△ 5 10 15 20 25 30 35 40 45 50

Cross shaft bearing ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★

Cross shaft mid bearing ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Cross shaft slip fork ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Front/rear leaf spring pin ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Kingpin of knuckle ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Ball pin of tie rod ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Ball pin of drag link ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Slide fork of steering drive shaft; cross shaft bearing ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Wheel hub bearing ★ ★ ★ ★ ★
Bearing in the front of input shaft of gearbox ☆ ★ ★ ★ ★ ★
Vehicle door hinges ★ ★ ★ ★ ★
Cab tilting lock mechanism ☆ ★ ★ ★ ★ ★
Bearing point, cab tilting torsion arm ☆ ★ ★ ★ ★ ★

Transmission clutch shifting fork shaft ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★

8-41
Maintenance period and data
Lubrication intervals (× 1000km)
Parts to be lubricated
△ 5 10 15 20 25 30 35 40 45 50

Transmission clutch releasing bearing (lubrication

☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
nozzle is on the clutch housing)

Lubricant and oil

Applied Parts Lubricant and oil Grade and model
CUMMINS Engine Diesel engine oil CH-4 level or more 15W/40
ZD30 Engine(EURO V) Diesel engine oil CH-4 level or more 5W/30 oil
ZD30 Engine(EURO VI) Diesel engine oil CK-4 level 5W/30 oil
CF-4 and above; when the environment temperature is above
D28 Engine Diesel engine oil —30°C, use 5W/30 oil; when environment temperature is
above —15°C, use 15W/40 oil
At -20 ℃ of environmental temperature or below: SL 5W/30 GB
Gasoline engines China-V and 11121-2006 gasoline engine;
Gasoline and engine oil
-VI of Liuzhou Automobile at -20 ℃ of environmental temperature or above: SL 10W/40
GB11121-2006 gasoline engine.
Quanchai diesel engines China-V CJ-4 or above and at ambient temperature: 15W-40 engine oil; at
Diesel engine oil
and -VI low temperature, recommended 0W-30 and 5W-40 engine oils.
Gearbox Manual Transmission API GL-4 or LAN-1 85W/90
Drive Axle Heavy-duty vehicle gear oil API GL-4 or GL-5 85W/90

8-42

Applied Parts
Steering gear
Power steering gear
Clutch and brake system
Each bearing and ball pin
Radiator and cooling system
Washer fluid
Lubricant and oil
Manual Transmission
Hydrodynamic drive oil
Synthetic brake fluid
General lithium base grease for vehicle 2#
Rust prevention antifreeze
Vehicle windshield glass detergent
Maintenance period and data
Grade and model
API GL-4 or LAN-1 85W/90
At ambient temperature higher than －20℃, use the 15W/40
CD or more grade; at ambient temperature of －20℃ or less,
use 8# D hydrodynamic drive oil.
HZY4 or DOT3 901-4
DF-2
SFFC- Ⅰ -20#

Engine lubricant
Choose grade API CH-4 or above diesel engine oil. The user may choose diesel engine oil of different viscosity grades
depending on the local environmental temperature. The recommended operating temperature range is shown in the
figure.

8-43
Maintenance period and data

Engine lubricant (for pressure common-rail fuel injection electronic-control engines)

It is recommended to use the quality SAE15W-40 heavy-duty engine multi-grade engine oil in compliance with the
CH-4/SF, CG-4/SF, SG, SH or SJ from API.
Engine oil classification and constitution
European Automobile
Cummins Engineering American Petroleum
Manufacturer’s Assessment
Standard (CES) institute (API)
Association (ACEA)
Lowest engine oil grade suitable for
CES-20075 API CF-4/SG ACEA E-2
medium-duty engine

8-44
 Maintenance period and data
ACEA E-3
CES-20071 API CG-4/SH Quality engine oil for medium-engine
ACEA E-5
Similar to CES-20071 in performance and
CES-20072 ACEA E-3 effective after European Test standard; for
quality engine oil of medium-duty engine

Recommended engine oil viscosity at the ambient temperature

Gear oil of drive axle

It is suggested to use the Sulfur-phosphorous type API GL-5 high-load gear oil. The applicable temperature for all kinds
of gear oil is shown below.

8-45
Maintenance period and data

Power steering oil

Use the API CD 15W/40 or better oil at the ambient temperature higher than -20 ℃; use general No.8 hydraulic drive
oil or No.8 D hydraulic drive oil at ambient temperature of -20 to -40 ℃.
Caution: one steering gear can only be filled with one kind of abovementioned fluid. Any mixed fluid could damage to
the oil seal, leading to leakage or making the steering booster invalid.
Grease
It is suggested to use the universal use lithium grease for the wheel hub and chassis.

8-46
 Maintenance period and data
Clutch booster fluid
It is suggested to use HZY4 or DOT4 901-4 synthetic brake fluid. Do not mix the brake fluid with different models or
from different manufacturers.
Engine antifreeze
It is suggested to use DF-2 anti-rust antifreeze. The freezing point of antifreeze should be less than the local
environment temperature by 8 ℃. Do not mix the antifreeze with different models

8-47
 Tightening torque

Tightening torque
Engine
Parts to be tightened Tightening torque (Nm)
Bolt for fan 24
Bolt for coolant pump 24
Bolt at the top of generator 43
Bolt beneath generator 24
Bolt for fuel - delivery pump 24
Joint between the fuel-delivery pipe and filter 32
Bolt for fuel injector 55
Bolt for fuel injection pump 24
Nut for timing gear of fuel injection pump 81
Bolt attaching the exhaust manifold to cylinder body 43
Screw plug for pressure-limiting valve 40
Oil drain plug 41
Bolt for crankshaft pulley 137
Bolt attaching flywheel to crankshaft 137
Bolt for starter 43

9-1
Tightening torque
Parts to be tightened Tightening torque (Nm)
Lock nut for valve adjusting bolt 24
Bolt for valve chamber cover 24
Bolt for crankshaft main bearing shell cover 176
Bolt for connecting-lever bearing cover 100
Bolt for flywheel housing 77
Bolts for cylinder head 126

Precautions
 If there is no lock washer, the tightening torque must be met.
 The threads of bolts must be lubricated during tightness. Do not use the damaged one.
 Alternatively tighten each bolt by the way of 2-3 steps
Cab and chassis
Applied Parts Tightening torque (N.m)
Oil drain plug 130~150
Large nut for Driving gear 350~500
Nut for steering drag link 120~140
Nut for the left and right steering arms 120~140
Bolt for front brake base 140~170

9-2
 Tightening torque
Applied Parts Tightening torque (N.m)
Bolt for rear brake base 156~206
Bolts attached to the bracket of valve chamber 55~70
Bolt for front brake chamber 55~70
Bolt for rear brake chamber 55~75
Bolts for the driven gear 140~160
Bolt for differential housing 140~160
Nut for lock pin 55~70
Lock nut for steering stopper 80~100
Nut attached to the steering ball pin 130~160
Nut attached to the tie rod clamp 40~60
Front adjusting nut 120~150
Rear adjusting nut 150~180
Screw for kingpin plug 40~60
U bolt and nut for front leaf spring 250~300
U bolt and nut for rear leaf spring 300~350
Nut for power steering inlet pipe (M18×1.5) 80
Nut for power steering outlet pipe (M16×1.5) 60
Tightening nut and bolt for steering knuckle arm 200~250

9-3
Tightening torque
Applied Parts Tightening torque (N.m)
Adjusting nut for front wheel hub bearing 120~150
Adjusting nut for rear wheel hub bearing 150~180
Ball pin nut for tie rod/drag link 192~226
Bolt and nut for axle shaft flange 55~70
Bolt attaching the reducer housing to axle housing 140~170
Bolt attaching the rear cover of axle housing to axle housing 90~120
Wheel nut (M20×1.5) 320~420
Wheel nut (M24×1.5) 420~490
Wheel nut (M30×1.5) 1000~1100

Caution: After running-in, under no load state, refer to the tightening torque to tighten the wheel nuts.
Caution: Every 10000km, under no load state, refer to the tightening torque to tighten the wheel nuts.

9-4
 Appendix 1: On-board Provision List

Appendix 1: On-board Provision List

S/N Part Name Quantity

On-board documents 1 Quality assurance manual and operation manual 1

2 5-tonnage jack 1
3 Tool bag 1
4 Double-end screwdriver assembly 1
5 Slip-joint pliers 1
On-board tools 6 Tyre crowbar and jack rocker 1
7 Socket wrenches for wheel bolts and nuts 1
8 Small adjustable wrench assembly (200 ×24) 1
9 Double-ended wrench (13 ×15) 1
10 Warning tag 1