DFSK K 2019 Series Service Manual
DFSK K 2019 Series Service Manual

DFSK K 2019 Series Service Manual

Extended cab truck
Table of Contents

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2019 DFSK Extended Cab Truck
- Service Manual -

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Table of Contents
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Summary of Contents for DFSK K 2019 Series

  • Page 1 2019 DFSK Extended Cab Truck - Service Manual -...
  • Page 2 IDENTIFICATION OF THE VEHICLE Contents Ⅰ. Identification of the vehicle 1. Identification of Number 2. VIN 3. Serial Number of the Engine Ⅱ. Main Technical Parameter A. Parameter of Mini Bus 1. Engine Parameters 2. General Function Index 3. Fuel consumption 4.
  • Page 3 IDENTIFICATION OF THE VEHICLE 5. Main weight Parameters 6. Wheel Alignment Parameters 7. Tyre Air Pressure 8. Capacity Parameters 9. A/C System Parameters B. Parameter of Mini Truck 1. Engine Parameters 2. General Function Index 3. Fuel consumption 4. Main Parameters 5.
  • Page 4 IDENTIFICATION OF THE VEHICLE 7. Tyre Air Pressure 8. Capacity Parameters Ⅲ.Vehicle Devices & Mechanics Operation 1. Door 2. Key 3. Front door window 4. Front door 5. Rear door window 6. Seat 7. Safety Belt 8. Dashboard 9. Fire switch - 4 -...
  • Page 5 IDENTIFICATION OF THE VEHICLE 10. Lighting, turning and high/low beam control pole 11. Wiper and cleaner control lever 12. Rear wind window wiper and cleaner switch 13. Horn 14. Emergency light switch 15. Fog light switch 16. Heating system 17. Control Board of heating system 18.
  • Page 6 IDENTIFICATION OF THE VEHICLE 22. Tool box 23. Inner light & interior rear view mirror 24. Interior top lamp 25. Outside rear view mirror 26. Sun shading board 27. Safe handgrip 28. Tool kit 29. Brake rod by hand 30. Pedal 31.
  • Page 7 IDENTIFICATION OF THE VEHICLE 1. Running-in 2. Start of the engine 3. Safety driving 4. Brake 5. Economy driving & environmental adaptability Ⅴ. Guide for Vehicle Operation 1. Fuel 2. Generator strap 3. Compressor belt 4. Engine oil 5. Engine belt 6.
  • Page 8 IDENTIFICATION OF THE VEHICLE 7. Thermostat 8. Transmission oil 9. Gasoline filter & oil supply tube & oil return tube 10. Air cleaner 11. Spark plug 12. Oil sprayer 13. Throttle valve block 14. Three-way converter 15. Electric fuel pump 16.
  • Page 9 IDENTIFICATION OF THE VEHICLE 19. Brake system 20. Tyre 21. Battery 22. Fuse 23. Air window cleaning liquid 24. Replacement of Bulb 25. ECU 26. Ignition timing 27. Usage of Jack 28. Extinguisher 29. Triangle warning plate 30. Operating controller - 9 -...
  • Page 10 IDENTIFICATION OF THE VEHICLE 31. Turning over and side Ⅵ . Check & Maintenance Service 1. Daily inspection 2. Regular check and maintenance 3. Regular maintenance period and items 4. Signs for maintenance 5. Maintenance Ⅶ. Analyzing & Eliminating the Malfunction 1.
  • Page 11 IDENTIFICATION OF THE VEHICLE 5. Malfunction of steering system, wheel and tyre system 6. Warm braw system failure 7. A/C system failure 8. Brake system failure 9. ABS system failure 10. Power system failure 11. Variety of lamps, light system failure, headlight failure Ⅷ...
  • Page 12 IDENTIFICATION OF THE VEHICLE Ⅸ. Maintenance of the Vehicle 1. Cleanness of the vehicle inside vinyl plastics Cleanup & Wax of the Vehicle’s Outer Part ............... - 12 -...
  • Page 13 IDENTIFICATION OF THE VEHICLE I.Identification of the Vehicle - 13 -...
  • Page 14 DENTIFICATION OF THE VEHICLE 1. Identification of Number 2. VIN 3. Serial Number of the Engine There are two VINs, one is on the The serial number of the Engine EQ 6 36 0 □□ aluminum plate which is on the right should be marked on the convexity of the front side of the Meter, and the other is rear lower part of the right cylinder.
  • Page 15 DENTIFICATION OF THE VEHICLE Ⅱ. Main Technical Parameter...
  • Page 16 DENTIFICATION OF THE VEHICLE A. Parameter of Mini Bus 1 . Engine Parameters Refer to the engine specification along with the vehicle Common performance parameter DFSK MINI BUS/SPECIAL BUS EQ636× EQ638× EQ640× EQ641× EQ639× EQ502× Items Unit ××series ××series ××series ××series...
  • Page 17 Main Technical Parameter of the Complete Vehicle 3. Fuel Consumption DFSK MINI BUS AND SPECIALLY SELECTED ENGINE Items Unit EQ474i/EQ474i-30 EQ465i2-30/EQ465i-21/AF10-06/EQ466i-30 BG13-20 Fuel Consumption L/100 (under limited ≤6.2 ≤6.5 condition) Note:As to the different practical condition, the real fuel consumption will be a little higher than the value above 4.
  • Page 18 Main Technical Parameter of the Complete Vehicle FR. Tread 1310 1410 1310 RR. Tread 1310 1410 1310 FR Suspension RR. Suspension 1000 5. Main Weight Parameters DFSK MINI BUS/SPECIAL BUS EQ636 EQ640 EQ639 Items Unit EQ641××× EQ502××× EQ638×××series ××× ××× ××× series...
  • Page 19 9°28′± Master pin ( °) 8° 8° inclination angle 30′ 2°50′± Master pin caster 2°30’ 2°30’ angle 30′ 7. Tyre Air Pressure DFSK MINI BUS MODELS EQ636× EQ638× EQ640× EQ641× Item Unit EQ639××× EQ502×××Series ×× ×× ×× ×× Series Series...
  • Page 20 Main Technical Parameter of the Complete Vehicle 8. Volume Parameters DFSK MINI BUS AND SPECIALLY SELECTED ENGINE Item Unit EQ465i-21/EQ465i2-30 AF10-06 EQ474i/EQ474i-30 BG13-20 EQ466i-30 Cool system of engine Lubrication system of engine 4.2~4.5 Fuel tank 40,50(Only for EQ6390PF Series) Lubrication oil of transmission box 1.3~1.5...
  • Page 21 Main Technical Parameter of the Complete Vehicle Compressor consuption W(Nc2000r/min) 2.13 1.58W(Nc1800r/min) 2.13 Idle Automatically r/min 950±50(465 engine) ,900±50(474 engine) Increase A/C water Temperature ℃ Protection Engine water Control Temperature ℃ Parameter Protection High Pressure Protection Low Pressure Protection Over-heating 150±5 150±5 150±5...
  • Page 22 Main Technical Parameter of the Complete Vehicle EQ502×××series include:EQ5021XXYF。 2. In order to meet the demands of the markets, the newly developed EQ636XXXseries, EQ638XXXseries and EQ640XXXseries adopt elective materials such as the front bumper bar (including rear bumper bar with those mini vans converted from mini buses), dashboard, luminaries, side-mirror, decoration boards and seat fabric.
  • Page 23 Main Technical Parameter of the Complete Vehicle B. Parameter of Mini Truck...
  • Page 24 Main Technical Parameter of the Complete Vehicle 1. Engine Parameter Refer to the engine manual distributed with the vehicle. 2. Common performance parameter DFSK truck and other special vehicle models EQ1021NF EQ1021TF × EQ502 × × × × EQ502 × × ×...
  • Page 25 (under limited condition) Note:As to the different practical condition, the real fuel consumption will be a little higher than the value above 4. Main Dimension DFSK truck and other special vehicle models EQ1021NF EQ1021TF × × EQ502 × × ×...
  • Page 26 Inner size of 2290× —— ×1440,1430, ×1330,1400, ×1440× 340,430 carriage 1440, 1400×1350 1440×340,430 5. Main weight parameter DFSK truck and other special vehicle models Item Unit EQ1020TF EQ1021NF EQ1021TF××× EQ1021GF24Q7 Truck Truck with double cabin Widened truck Truck Curb weight 910,900,880...
  • Page 27 Main Technical Parameter of the Complete Vehicle 6. Wheel Alignment parameter DFSK truck and other special vehicle models Item Unit EQ1020TF EQ1021NF EQ1021TF××× EQ1021GF24Q7 Truck Truck with double cabin Widened truck Truck Toe-in 0~5 Tire camber 1°30’ 42′±30′ 1°30’ angle...
  • Page 28 Main Technical Parameter of the Complete Vehicle 8. Volume parameter Item Elective engines for DFSK truck and special truck models Unit EQ465i2-30/EQ465i-21 AF10-06 EQ474i-30/EQ474i BG13-20 Cool system of engine Lubrication 4.2~4.5 system of engine Fuel tank Lubrication oil of 1.3~1.5...
  • Page 29 Main Technical Parameter of the Complete Vehicle Ⅲ 、Vehicle Devices & Mechanics Operation...
  • Page 30 Main Technical Parameter of the Complete Vehicle Door While locking the front and back door without key outside the vehicles, the Open locking buttion shall be pressed down Lock while the door is open, and pull up the window, then close the door. Note:...
  • Page 31 Main Technical Parameter of the Complete Vehicle on the inner side of the door. Turn the handlebar clockwise counter-clockwise, the door window will come up or come down. Front Door Press down the button 4, then button 3 The windows of rear doors are can not work, press again, then the controlled by the inner handle, the button 3 is workable.
  • Page 32 Main Technical Parameter of the Complete Vehicle two pothooks hook the button, and then fasten it. It is for three passengers, while folded the Adjustment of the Front Row extra one, pull outward the backrest locking Seats: device and fold the backrest horizonally, Pull up the movable adjustable handle, then pull forward the outward handle under the seat, fold the seat well and make it close...
  • Page 33 Main Technical Parameter of the Complete Vehicle requirements.While undo the safety automatically. belt; press the release button on the lock catch. The customers should not do any amendments; otherwise it may cause the safety belt not being adjusted which will influence elasticity. 座椅锁闩...
  • Page 34 Main Technical Parameter of the Complete Vehicle to the human body skeleton, (See the Do not use the deformed saferty belt. Safety belt should be prevented from polishing compound, grease spot, chemical picture). Please note that, the waise One safety belt is only for one person, article, especially storage battery sour liquid band part shall not be across the tie the children on knee of passenger...
  • Page 35 Main Technical Parameter of the Complete Vehicle ○ 8. Dashboard Emergency Switch 9、Side Intake 8. Dashboard ① of cabin ) ( One and half Assembled Meter 10、Centre Intake ② Ignition Switch 11、A/C Switch ③ Lighting/Turning high/low 12、Switch Assy Defroster beam converting switch 13、Rear For Switch ④...
  • Page 36 Main Technical Parameter of the Complete Vehicle the wiring can be put through and the engine prepares to run. 4. ‘Start’: On this position, the engine is started by the starter, once the engine starts. Please loose the key which will return to ‘on’automatically. Do not keep the ignition key in’ON’position for a long time unless the engine is running, or else, the...
  • Page 37 Main Technical Parameter of the Complete Vehicle control pole be loosen, when there is no lotion but turn on thecontrol pole will lead damage to the generator. If attempting to clean the dash by wiper will lead damage to the wiper and glass. The first step should be the wet of glass then start the wiper.
  • Page 38 Main Technical Parameter of the Complete Vehicle No cleaner and single-arm wiper installed to rear wind window. Press the wiper switch (on the dash board) one time, the rear wind window wiper starts to work. Press wiper switch another time, the rear wind window wiper stops.
  • Page 39 Main Technical Parameter of the Complete Vehicle Press down the button, all the four The horn button is on the wheel turning lights and the side turning Press the emergency light, all the lights glitter simultaneously. Press the panel four turning lights and sideway other end will turn off the lights.
  • Page 40 Main Technical Parameter of the Complete Vehicle the indicator light. second gear, and press the foglight Rear Foglight switch, the foglight will be turned on, Turn the headlight switch to the second gear, and press the foglight and so will the indicator light; press switch, the foglight will be turned on, again, the foglight is turned off, so is and so will the indicator light;...
  • Page 41 Vehicle Devicesxs and Mechanics Operation ①Windshield defrosting air door ②The central vent hole ③The side defrost vent hole ④The broad vent hole...
  • Page 42 Vehicle Devicesxs and Mechanics Operation 17.Control Board of Heating the defrost exthaust port of windscreen gas vent. System Note: and side defrost exhaust port. The time for blowing should not be ⑤ Defrost too long while the air is in inner ⑥...
  • Page 43 Vehicle Devicesxs and Mechanics Operation Control the rotate speed of fan, that is , directions: Cold air is sent off from the windscreen and side defrost exhaust adjust the draft. centre intake, and the warm air is sent port. ⑨ Optional Button for ⑤...
  • Page 44 Vehicle Devicesxs and Mechanics Operation Assembled Meter The speedometer expresses with km/h ( One and half the speed of the automobile. cabin ) Odometer The odometer has six -figure number ① Speedometer in all to show the total driving mileage, ②...
  • Page 45 Vehicle Devicesxs and Mechanics Operation While driving, water While pointer tempreture should be kept in the ‘F’position, it shows that the fuel tank normal scope, that is: between ‘C’& is full of fuel; while at the position of ‘H’. When the pointer moves to ‘E’, it shows the fuel tank is empty ‘H’direction and exceeds the scope, it means the engine too hot, you should...
  • Page 46 Vehicle Devicesxs and Mechanics Operation in all to show the total driving mileage, the minimum unit of mileage is 1km. Assembled Meter Odometer after finishing caculation , count again since " 0 " , analogize sequentially to count for the first time. The short odometer has four figures to show the speed.
  • Page 47 Vehicle Devicesxs and Mechanics Operation 18. Assembled Meter ‘H’. When the pointer moves to ‘H’direction and exceeds the scope, it means the engine too hot, you should stop the vehicle. 18. Assembled Meter While the pointer at the ‘F’position, it Chart 1 shows that the fuel tank is full of fuel;...
  • Page 48 Vehicle Devicesxs and Mechanics Operation 18. Assembled Meter When every headlight adopts high When ignition switch puts through, beam dipped headlight, this When putting ignition switch through, this indicator lamp lights immediately, indicator light will be on. this indicator lamp lights immediately, and engine goes out immediately after 18.
  • Page 49 Vehicle Devicesxs and Mechanics Operation 18. Assembled Meter Note It shows the brake system Note: breaks down when the ignition this situation, switch is on the position of necessary need longer ‘ON’or ‘START’ parking distance, more powerful indicator light is not on or it is pedal force and longer pedal not out after the engine starts or stroke.
  • Page 50 Vehicle Devicesxs and Mechanics Operation indicator lamp will go out, if the position. 20. Cigarette Ash Box trouble indicator lamp does not go out while the vehicle starts or lights in the course of running, it shows the engine control module breaks down , please ask Dongfeng YUAN Maintainer for While the ignition switch is in the position of put-through and the...
  • Page 51 Vehicle Devicesxs and Mechanics Operation (12)USB Put the cigarette end into the ash box after going out. While clearing up, 22. Tool Box press the ash box spring down, you can pull out the box. Hold the ash box 1. Electric Source Switch & Volume vertically and insert it to the groove until clenching the teeth of the trough.
  • Page 52 Vehicle Devicesxs and Mechanics Operation Regard the inner mirror and inner rear The indoor light button consists of view mirror as a combination and it is three pieces of shelf location. set up in the middle of the top of wind “OFF"...
  • Page 53 Vehicle Devicesxs and Mechanics Operation 24. Interior Top Lamp that you can see the behind vehicles or other objects through it. And the Safe handgrip is located on the upper side surface of the outer rear-view mirror is of each seat (The driver’s side doesn’t protruding surface.
  • Page 54 Vehicle Devicesxs and Mechanics Operation ① Tool Bag ② Plier ③ Hatch Spanner12×14 ○ 4 Screwdriver ○ 5 Handlebar of Screwdriver Draw up the brake rod, the vehicle Clutch Pedal ○ 6 Handlebar of Sleeve will stop; when release the stopping Clutch pedal can break transmission of ○...
  • Page 55 Vehicle Devicesxs and Mechanics Operation accelerator pedal, the rotating speed of Reverse gear: pull towards left the engine will increase and the output 32. Front Storehouse Cover power will go up 31. Shift Handlebar gear: first pull towards to left and The handle of front storehouse lies then push forward.
  • Page 56 Vehicle Devicesxs and Mechanics Operation Ⅳ 、Operation of the Vehicle...
  • Page 57 Vehicle Devicesxs and Mechanics Operation 1.Running-in The first Gear 2500 In the course of car running-in, we use Note: kilometers the best material, every part is Once the engine starts, please processed meticulously, but before Gear 1 15Km/h release the ignition key to disconnect Recommended letting the engine bear peak load, each Gear 2...
  • Page 58 Guide for Vehicle Operation under any circumstance.. parking at the slope which may after starting, the curb idling will be ② If you can't start engine while damage the clutch. normal, and then repeat the above trying several times, the engine might While driving the vehicle, drivers course.
  • Page 59 Guide for Vehicle Operation and rear brake will work at the same lower the fuel consumption: time. If there are shrieks some times ① Avoid running idle for a long time: while braking, it is because of humidity of the road surface or cold If you don’t drive the vehicle after and snow weather etc.
  • Page 60 Guide for Vehicle Operation Driving on the icy road low gear promptly according to the the resistance for driving will increase You can use the tire tyre chain in slope and the rotational speed of which may cause the waste of the fuel, order to prevent the tire sliding on the engine in case that the engine icy road.
  • Page 61 Guide for Vehicle Operation...
  • Page 62 Guide for Vehicle Operation Ⅴ . Guide for Vehicle Operation...
  • Page 63 Guide for Vehicle Operation 1.Fuel damaged, and method of adjusting and about 6-9mm and assure there is no changing of the belt are as follows: any damage to the belt. If the belt 1. Unclamp the three setscrews of the generator.
  • Page 64 Check/Maintenance Service petrol machine use and maintain the manual. Engine Belt 7. Thermostat Note: Note: In order to make oil filter fasten dangerous properlr, the more important thing discharge the radiator cover is to mark the position while the while the temperature of the small filter rubber washer meets water is very high, because the the installing surface and the oil...
  • Page 65 Check/Maintenance Service There is 0.3MPa in the oil supply The filter element of the air cleaner system. While changing gasoline filter and should be often removed and washed. The spark plug is F6TC (4C7T) and oil supply tube and oil return tube and tie-in, Wash once when running 10000KM the whorl is M14 *1.
  • Page 66 Check/Maintenance Service gather the charcoal powder in the exposed whorl part. In this way, when Note: Every performance index of air throttle has been adjusted qualifiedly According to the situation of the already when the engine is dispatched from the factory. The user is not imported vehicles euipped...
  • Page 67 Check/Maintenance Service which should be adjusted. of exhaust from engine; three-way 18.ABS convertor can reduce the harmful gas ABS (Antilock Braking System, ABS effectively. for short) can prevent wheel from braking completely suddenly automatically and repeatedly adjusting It is quite easy for three-way convertor the braking pressure and fully utilize to be overheated while the gasolines peak value of the adhesion coefficient...
  • Page 68 Check/Maintenance Service On decorating road, the braking stepping on the brake pedal by 294N Note: distance of vehicle with ordinary (30kg) When ABS loses its function, the braking system will be shorter than performance of brake system is same that of vehicle with ABS. with that of the common brak system.
  • Page 69 Check/Maintenance Service brake totally, there should be no sense worn and torn and lengthen its service ① Check the wearing and tearing of of being blocked. life, please make tires the flower stria to make certain that if 20. Tyre transposition when it is running every 10000km and adjust the air pressure of it should be changed or not.
  • Page 70 Check/Maintenance Service the connection end and erosion will cause poor contact. If the the white power is found at the connection end, it should be clean up and then spread lubricate grease or waseline. 22. Fuse The spare tire is put under the floor of the back of the vehicle, screw the fixed screw on the rear pumper counter-clockwise and put down the...
  • Page 71 Check/Maintenance Service Note 22. Fuse Note If the major fuse is burnt, In order to guarantee that the users should replace it Note there spare fuse instead of using the wire etc as If the electric machine works replacement, three 10amp and substitute which may cause the without cleaning liquid, it will 15amp fuses will be prepared in...
  • Page 72 Check/Maintenance Service be simply pulled out or inserted in. While removing the round bulb from the socket, please first press the bulb in and then contrarotate a little and then pull out. 24. Replacement of Bulb Push forward the rear fixing foot after breaking off relations, take out box cover backward, you can lift off 24.
  • Page 73 Check/Maintenance Service...
  • Page 74 Check/Maintenance Service tailstock of the turning lights and then Don't electrification is it dial ECU plug to insert, is it is it " blow fire " removes the bulbs for replacement way carry on circuit is it check to set 25.
  • Page 75 Check/Maintenance Service And any person shall not be under yellow is pressuer over high, red over have been fixed up firmly the vehicle while jacking up to low, should be changed. While using the jack, the vehicle shall prevent the damage to people be put in the horizontal and hard 28.
  • Page 76 Check/Maintenance Service Press UP botton, and keep the normal speed. When trun over to some angle, 31 .Trurning Over and Side ① Pull switch to ON. tightwire pull the switch to limit the ① Stop the car on flat floor. location, then hydranlic...
  • Page 77 Check/Maintenance Service groove when turn the cargo box to regarding connecting rod as axle ① Side plate opened by manual. left,with ring of loctation limited, then rotation that makes latch hook rotate There are lock on the side plate, and put the double groove bolt into left at the same time, and makes latch lock with cargo box.
  • Page 78 Check/Maintenance Service safety. under the vehicle. explosive or sticky material are Notice: when the dumper is at allowed to be transported by work, the surrounded dumper truck; environment should be noticed , Notice : If the cargo box can if there are flammable things not be lowered due to the battery around the dump are forbidden.
  • Page 79 Check/Maintenance Service operations are allowed to the alarming; cargo box。 External lubricating spot : 1) ball joint hydraulic cylinder;2)joint of frame ball joint and the stand ball joint;3) latching mechanism of the cargo box; Rated wattage of the hydraulic Notice : Unauthorized type of lubricant and the motor:800W;...
  • Page 80 Check/Maintenance Service recommended by the manufacturer or l) (3) To maintain the cleanliness of hydraulic Storage and use, fuel containers and the product supply applies to the pump systems, shou be the timely removal the tools must be clean to prevent oil load limits.
  • Page 81 Check/Maintenance Service Period Km×1000 Items moon count as standard confirm 1. Daliy inspection Failure maintain time form. Every inspection , ○ Daliy inspection is a necessary Fuel Level adjust , lubricate should stipulated ○ work for driver. The conditions of the Door Lock time go on according to form strictly ○...
  • Page 82 Check/Maintenance Service Months Engine 1.Fan ( Water Pump、 Compressor) — — — — Drive Branch Belt ( Strain 、 Abrasion ) Camshfte Synchronization — J.T.G — J.T.G — J.T.G — J.T.G Tooth Belt(Strain, abrasion, damage) *3. Valve Gap — J.T. —...
  • Page 83 Check/Maintenance Service Fuel System Cement or asphaltum Clean while driving for every10000km, replace for every 40000km Cleaner road Gravel Road Clean while driving 25000km, replace for every 40000km *14. Fuel Box, fuel pipe and tie-in J.T.G — — J.T.G — —...
  • Page 84 Check/Maintenance Service Cable *24. front: Brake disk & cliper J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G *25. Rear: Brake Drum & J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G Brake Shoes *26. Brake Soft Pipe & J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G...
  • Page 85 Check/Maintenance Service Periods Km×1000 Items monthes *29.Bolt & Nut(Elasiticity) — — — — *30. Steering Wheel(Gap, J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G Elasiticity) Cooling System *31. Refrigerant *32.Brake System J.T. J.T. J.T.G J.T. J.T. J.T. J.T. J.T.G J.T.G J.T.G *33.Compressor —...
  • Page 86 Emergency Measurement Ⅶ 、Analyzing & Eliminating the Malfunction 1 、 Malfunction of Engine System Problems Reasons Solutions Starting Problems Replace 1、Failure of Ignition System Repair or Replace 1.1 Damage of the Protecting Device Repair or Replace 1.2 Failure of the Spark Plug Replace 1.3 Joint of High Voltage Damping Wire Loose or being Damaged...
  • Page 87 Emergency Measurement 2.5Impurity Fuel (eg. Including water) Rectify 3. Lack of Crock Pressure Screw Down or Replace 3.1 Spark Plug not Screw Down or Damage of Adjustment Gasket Repair or Replace 3.2 Incorrect Valve Gap Repair or Replace 3.3 Leakage of Cylinder Cover Gasket 3.4 Piston, piston ring or abrasion of Cylinder 4.Others 4.1 Rupture of Timing Belt...
  • Page 88 Emergency Measurement 4. Others 4.1 Brake Problems Repair or Replace 4.2 Clutch Skidding Adjust or Replace 4.3 Connect Flex or Vacuum Soft Pipe Break Off Reliable Connect Unstable Idle Speed of 1. Trouble with Fuel System Engine 1.1 Block of the Air Cleaner Clean or Replace 1.2 Leakage of Intake Branch Pipe Replace...
  • Page 89 Emergency Measurement 3. Rod Noise 3.1 Rod Bearing Abrasion Replace 3.2 Winch Pin Abrasion Repair or Replace 4.Crank Shaft Noise 4.1 Bearing Abrasion Replace 4.2 Crank Shaft Neck Abrasion Repair or Replace 4.3 Bearing cover bolt flex Screw Down 4.4 Gas of crank shaft thrust-piece too big Replace the thrust-piece Engine Superheating 1.
  • Page 90 Emergency Measurement Replace the Sealling Glue Seal Glue of Oil Case deterporate or Break Replace 1.4 Leaking of Oil Seal Replace 1.5 Damage of the Cylinder Gasket Screw Down 1.6 Engine Oil Filter not being Screwing down Screw Down 1.7 Leaking of the Engine Oil Pressure Annunciator Screw Down or Replace 1.8Oil Leaking of Cylinder Cover Screw Down...
  • Page 91 Emergency Measurement 4.1 Poor Valve Seat Repair or Replace 4.2 Brake Seizure Repair or Replace 4.3 Malfunction of Thermostat Replace 4.4 Abnormal Tyre Pressure Adjust 2. Clutch problems problems reasons solution Clutch Skid Inproper stroke of Clutch Pedal Adjust the Free Stroke Clutch Flake Abrased or with Oily Soil Replace Clutch Flake Deformation of Compressive Plate or Flywheel...
  • Page 92 Emergency Measurement Vibration of Clutch Brightening of Clutch Flake (Like Glass) Repair or Replace the Clutch Flake Clutch Flake with Oily Soil Replace Clutch Flake Separate Bearing Smoothly Skid on the Guard Ring Lubricate or Replace Input Shaft of Input Shaft Bearing Bearing Guard Ring Sway of Clutch Flake or Poor Connection Replace Clutch Flake...
  • Page 93 Emergency Measurement 3. Malfunction of Transmission Problems Reasons Solutions Off Gear Abrasion of Gearshift Forked Shaft Replace Abrasion of Gearshift Fork or Synchronizer Gear Replace Cover Replace Elasticity of Setting Spring Weakened or damaged Replace Abrasion of Input shaft or Main Shaft Bearing Replace Abrasion of Tooth Sleeve etc.
  • Page 94 Emergency Measurement 4. Malfunction of Differential Gear Problems reasons solution Gear Noise Gear Oil going bad or including water Replace Oil & Re-infuse Insufficient Gear Oil or Incorrect Kind Replace Oil or Infuse Incorrect Gap between Taper Driving Gear & its Adjust Driven Gear Adjust or Replace...
  • Page 95 Emergency Measurement 5. Malfunction of Steering System, Suspension System, Wheel and Tyre System Problems Reasons Solutions Wheel Tyre not matching or Asymmetry Replace Running(deviating ) Inproper Tyre Pressure Adjust the Tyre Air Pressure Rupture of Spring Replace the Spring Belt Tyre Warped by Transverse Force Replace the Tyre Maladjustment of Front Wheel Alignment Check &...
  • Page 96 Emergency Measurement Replace Wheel or Tyre Adjust Air Pressure of Tyre Wheel Shocked Inproper Strut (Shock Absorber) Replace Tyre Replace Strut Front Wheel Shake or Imbalance of Tyre or Wheel Banace the wheel or replace the tire Jump Abrasion or Damage of Wheel Bearing and/or wheel Abrasion of Steering Horizontal Coupling Bar Replace the wheel bearing...
  • Page 97 Emergency Measurement Turning Windage too Big Abrasion of Wheel Bearing Replace Wheel Bearing Bolt of Turning Gear Case Loosened Screw Down Incorrect Adjustment of Rack & Pinion Check & Adjust Torque of Rack & Abrasion of Turning Axle Universal Joint Pinion Abrasion of the turning sidelong coupling bar end Replace Universal Joint...
  • Page 98 Emergency Measurement Abnormal Noise with Abrasion of unworkable or loose of the turning Replace the Turning Sidelong Coupling global Bar End, Front Suspension Arm, Front Wheel sidelong coupling bar end, global joint (left/right joint tramsmission shaft joint. front suspension arm), inner side global joint of the Repair or Replace coupling bar or tramsmission shaft joint.
  • Page 99 Emergency Measurement Turning Instable while Abrasion of Wheel Bearing Replace Wheel Bearing Brake Damage or Sagging of Spring Replace Spring Charge of Tyre Insufficient Charge the Tyre to Proper Pressure Front Wheel Alignment Inproper Check & Adjust Front Wheel Alignment Height of the actural Rupture or Sagging of Spring Replace Spring...
  • Page 100 Emergency Measurement 6. Warm braw system failure problems causes resolution when the warm-braw fan fan fusing change fuse, check short circuit puts through the power fan resistance doesn’t work check circuit condition it doesn’t work fan monitor doesn’t work change monitor circuit or ground connctoion failure repair when necessary output temperature is...
  • Page 101 Emergency Measurement no cooling air output (AC AC doesn’t work Recall, pump-out and fill in cryogen. doesn’t work) 1) no cryogen check the fuse,heating ventilation 2) fusing change AC fuse and check 3) the switch of AC and fan are wrong short-circuit or not 4) low idling check AC and fan switch...
  • Page 102 Emergency Measurement blowing machine module doesn’t work check blowing machine module 1) blowing machine module resistance is wrong resistance 2) ACand fan switch is wrong check AC and fan switch 3) circuit or ground connection is wrong repair as needed 4) blowing machine module is wrong check blowing machine module No cooling air or not cool...
  • Page 103 Emergency Measurement cooling air output off and Failur of the connection of the circuit Repair when necessary Failur of the expansion valve Check the expansion valve Excessice moisture in the AC system Change the fluid/airer, refill the Failur of the disconnection switch of high-speed cryogen Failur of the AC controller Check...
  • Page 104 Emergency Measurement No cool air only during Failure of the disconnection switch of high speed Check the disconnection switch of high-speed driving Excessive refill of the cryogen high speed Freezing of the evaporator Check the cryogen Check the evaporator Check the thermistor of AC Cool air not strong Jam in the evaporator Check the evaporator...
  • Page 105 Emergency Measurement Noise The bearing fails Replace electromagnetic clutch Clutch disk damaged Replace Inadequate cool air The gasket is damaged Replace The leaf valve fails Replace No rotation The rotary valve is blocked, causing the jam of the Replace cylinder and/or the axle Replace The electromagnetic clutch is stuck Replace...
  • Page 106 Emergency Measurement Oil or fluid leak Sealing of the axle is damaged Replace O ring damaged Replace Brake system failure Problem Reasons Treatment mothod Noise when braking Brake pipe leakage Identify and repair leaking parts Brake disc or brake pad (block) dirted by the oil Clean or replace Brakes overheating Repair or replacement...
  • Page 107 Emergency Measurement Uneven brake (brake work Brake pad (block) friction lining and / or the brake replacement uncoordinated) shoe linings of water or oil Check the automatic adjustment of Brake drum brake and brake shoe clearance disorders mechanical (automatic adjustment of mechanical failure) Replacement Brake disc brake and / or loss of brake drum circle Uniform inflation...
  • Page 108 Emergency Measurement Too much pedal travel Partial failure of brake system Check the brake system, when necessary, Inside the brake master cylinder brake fluid reservoir for repairs. insufficient Brake fluid with a qualified endorsement. An air brake system (pedal like riding in the sponge on Check brake system for leaks, with or the weak) without air.
  • Page 109 Emergency Measurement Pedal hopping (when the Damage or loose wheel bearings Replace wheel bearings brake pedal beat) After steering knuckle or axle deformation After the replacement of steering knuckle Radial brake disc is too large or does not meet the or axle technical requirements of parallel Check, if you do not meet the technical...
  • Page 110 Emergency Measurement After starting the engine ABS (Antilock Braking System) fault Refer to ABS System ABS warning light (if fitted) Implementation ABS (Antilock Braking System) fault Refer to ABS System braking, warning light (if fitted) 9. ABS system failure (optional) Check 1 Steps Operation...
  • Page 111 Emergency Measurement Proceed to step 4 Open-type short circuit grounding 1)Disconnect the ignition switch 2 ) Connect ABS wheel sensor connectors connect 3)Measure the resistance between positive terminal of ABS wheel speed sensors and plug connector module negative, between positive terminal and ground.
  • Page 112 Emergency Measurement See chapter "front wheel speed sensor With a well-known Replace the sensor and re-check. information" content, check that the output control voltage or waveform. module replaced and re-check Check 2 Steps Operation Proceed to step 2 Exclude or replace the ABS hydraulic 1)Turn the ignition switch off, remove the unit device from the ABS hydraulic connectors.
  • Page 113 Emergency Measurement Proceed to step 4 "R", "R / W", "B1", "B1 / W", "Y", or "Y 1 ) Remove the ABS control module / W" short circuits and power supply connector 2)Check the ABS control module terminal "A1", "A2", "A7", "A8", "B12", "B13", whether the current valve circuit connected correctly.
  • Page 114 Emergency Measurement When the engine is running, charging Loose or worn drive belt Adjust or replace drive belt light does not go out (batteries need IC regulator or alternator failure Check charging system frequent recharging) Line fault Repair line 11、Variety of lamps, light system failure Headlight failure Problem Reason...
  • Page 115 Emergency Measurement Front anti-fog lamp doesn’t work Bulb damage Check the lamp Fog light fuse blown Check the fuse, if necessary, should be Front anti-fog lamp switch doesn’t replaced. (If replacement, check if it’s work short-circuit) Front anti-fog lamp relay doesn’t work Check front anti-fog lamp switch Front headlamp switch doesn’t work Check relay...
  • Page 116 Emergency Measurement fuse On or resistance between battery and switch is too large Turn signal / alarm relay faulty Combination switch or alarm switch doesn’t work Flash frequency is too low Supply voltage is too low Check recharging system Turn signal / urgency alarm relay faulty Check relay Problems Reasons...
  • Page 117 Emergency Measurement ABS warning light will be Trouble with ABS Please see ABS while starting engine (if it has) ABS warning light will be Trouble with ABS Please see ABS on while braking(if it has)
  • Page 118 Emergency Measurement Ⅷ 、Disposition of Emergency 1. Starting System Not Work headlight is opened, try to turn thee state. If headlight becomes too dark or ignition switch to " START " position goes out totally, it generally shows the ① In a situation that the in order to confirm the storage battery storage battery electricity exhaust or...
  • Page 119 Emergency Measurement poor connecting of wiring end. After not bend over the battery. respectively. Pay attention that the ② Confirmation, charge storage cable shall not be near to the belt Do not expose the battery to direct battery or repair the connect point. pulley, belt or fan.
  • Page 120 Emergency Measurement the temperature form of the engine is letting out is found, it is forbidden to pointedkout beyond the regulated value, so: use the engine before getting rid of the ① Turn off the A/C. trouble. ③ Parking the vehicle in a safe place, and make the engine running for If no leaking is found, you can several minutes at idle speed till...
  • Page 121 Emergency Measurement firmly by special lock framework. Note If you use the front traction euippment Unless emergency, do not tow the While the vehicle is dragged away, the to tow from the front part, the rear vehicle transporting pothook wheel shall be fixed to a moveable front wheels land and the rear generally.
  • Page 122 Vehicle Protection Ⅸ 、Maintenance of the Vehicle...
  • Page 123 Vehicle Protection Cleanness of the Vehicle Inside ③ water & neutral soap from ethylene The scratch of the body Vinyl Plastics plastic. Make the dirt soft with brush, caused by dirt or other things may Make the spare liquor by mixing and then, washes the floor cushion result in rust.
  • Page 124 Vehicle Protection with sponge or soft cloth which some goods like corrosivity material dipped into neutral detergent or wash Waxing articles, such as chemical article, soap for petrol gently. fertilizer, cleaning the article , alkali , You are advised to make the ④...

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