DongFeng EQ1040GLJ4-CMD1-D User manual

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Preface
Thank you for using Dongfeng Brand mini truck. Dongfeng Mini Truck is the new generation product
manufactured by Dongfeng Vehicle Co.,Ltd., safety, reliable, comfort driving and high performance.
For better operation and maintenance the products, the operation manual is carried out. The book
introduces the driving operation, maintenance, assembly and regulation, malfunction analysis etc,.
Please read it carefully before operation, master the operation method quickly, maintenance and repair
the vehicle regularly according to the suggestion to ensure the security of truck, prolong the operation
life of vehicle.
With the development of technological progress, Dongfeng Mini Truck makes improvement and
perfection, and it may occur different between the Operation Manual Introduction with the actual
structure of vehicle, if any different, we will amend.
Dongfeng Vehicle Co., Ltd.
October, 2011

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Statement
Dongfeng Vehicle Co., Ltd. will not responsible for the reliability, security and adaptability of the
vehicle if the following condition occurs:
1. Without permission, customer changes or modifies the design of machine;
2. Original spare parts, approved convertible parts or components instead by other parts;
3. Over loading during the operation.
Symbol stipulated in the manual as follows:
Note: It may cause personal injury or the damage for the parts and the vehicle if do not comply with
and pay attention to the matter which symbol stipulated.
Warning: It may cause serious personal injury or great property loss if do not comply with the
matters which Warning stipulated.

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Content
ⅠOverview of Vehicle.......................................................................................................................................... 5
ⅡMain Parameters............................................................................................................................................... 6
1. Fuel ........................................................................................................................................................... 6
2. Location of Nameplate, VIN and Engine Number.............................................................................. 6
3. Vehicle Technical Parameters (Model EQ1040GLJ4-CMD1-D)....................................................... 7
ⅢOperations.......................................................................................................................................................... 8
1. Various devices and mechanism operations....................................................................................... 8
2 Vehicle use................................................................................................................................................. 31
ⅣMaintenance and Inspection......................................................................................................................... 37
1. Regularly safety precautions of routine maintenance..................................................................... 38
2. Routine maintenance............................................................................................................................ 39
3. Periodic Maintenance........................................................................................................................... 39
ⅤMalfunction Analysis and Elimination............................................................................................................. 53
1. Malfunction of Engine System (Please refer to Engine Operating Instruction Manual)............. 53
2. Malfunction of Clutch System.............................................................................................................. 53
3. Malfunction of Gearbox System.......................................................................................................... 55
4. Malfunction of Compensating Gear System..................................................................................... 56
5. Malfunction of Steering mechanism, Suspension, Wheel and Tire System................................. 57

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6. Malfunction of Braking System ........................................................................................................... 60
7. Malfunction of Power Supply System ................................................................................................ 62
8. All sorts of light fitting malfunction...................................................................................................... 63
9. Accessories malfunction...................................................................................................................... 66
ⅥEmergency Treatments.................................................................................................................................. 67
1. Tire replacement ................................................................................................................................... 67
2. Bridge connection starting................................................................................................................... 68
3. Engine overheat.................................................................................................................................... 69
ⅦBody Maintenance.......................................................................................................................................... 71
1. Measures of protection......................................................................................................................... 71
2. Vehicle interior cleaning....................................................................................................................... 72
3. Body cleaning........................................................................................................................................ 72
ⅧFuel and Lubricating Oil, Vehicle Mounted Tools....................................................................................... 74
1. Fuel/lubricating oil/coolant/scrubbing solution.................................................................................. 74
2. Vehicle mounted tools list.................................................................................................................... 75

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ⅠOverview of Vehicle
Dongfeng mini truck is a new developed and designed product of Dongfeng Vehicle Co., Ltd.
The truck is the most ideal tool for short distance transporting in modern city and countryside with right
hand steering wheel and hydraulic braking truck. Unique outlook，novel modeling, flexible steering, good
stability, strong power, good mobility, small turning diameter, strong gradeability, high driving speed, low
noise, low fuel consumption, smooth and comfort running.
The humanized design of Dongfeng mini truck gives the driver to experience more driving pleasure; the
cab uses full seal structure. It has the natural ventilation system, various striking meters and indicators,
complete and convenient switches, graceful artistic color of the internal body, and the chair is designed
according to the modern human body engineering theory, comfortable riding and open vision.

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ⅡMain Parameters
1. Fuel
It should adopt with different type of light diesel with the national standards under different
temperature.
When the ambient temperature is ≥4℃,it should use type 0 light diesels;
When the ambient temperature is <4℃,it should use type -10 light diesel;
When the ambient temperature is <-5℃, it should use type -20 light diesel;
2. Location of Nameplate, VIN and Engine Number
2.1 The data plate should be located at the middle of the internal cab of the right side column.
2.2 The vehicle identification number should hit in the middle front part of the frame right-side

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beam.
2.3 The engine number is on the engine data plate.
3. Vehicle Technical Parameters (Model EQ1040GLJ4-CMD1-D)
Items Units Basic Parameters
Dimension
Overall dimension Length
mm
4700
Width 1770
Height 2100
Internal body
dimension
Length 2800
Width 1650
Height 400
Wheel base 2850
Front tread 1400
Rear tread 1278
Rear suspension 1295
Weight Parameter Unload weight kg 1500

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Loading weight 2320
Factory standard max. total weight 3950
No. of passengers(including the driver) person 2
Other Parameters Tire specification 6.00-14
Engine model/power/output volume YD480B/29kw/1809ml
ⅢOperations
The vehicle should be operated with the following
requirements and methods.
1. Various devices and mechanism
operations
1.1 Door
When the door opens from outside, insert the key to

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the locking hole under the outdoor handle of the cab, turn the key, the door will be unlocked, and
then draw the door handle, the door opens. As show in picture:
Insert the key in the locking hole and turn it reversely to deadlock the door. It also works without the
key, only have to press down the locking button, pull up the door handle, then close the door, the
door deadlocks.
Locking buttons are set on all the door glasses; press this button, the door will deadlocks. At that
time, both outside and inside door handles could not open the door. As show in picture:
When the door opens, pull up locking button, then draw the handle, the door opens.
Warning Do not left the key in the car.

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During travelling, take the key out of the ignition switch is forbidden.
1.2 Door Glass Lifter
The glass lifter handle is located inside of the door, the glasses will
raise or lower when turns the handle. As show in picture:
1.3 Chair
The chair divides into the seat back cushion and the seat cushion. The
seat back cushion fixedly installs on the chair bottom plate, the seat back cushion may turn over
forward, and rotation handle is in the flank of the chair. Behind the bottom plate, there are two
rotating joints fixed on the rear beam of the frame chair. Two hooks in front, the handle buckle are
installed on the front beam of the seat cushion in order to fix the seat cushion. The driver’s side
chair can be forward and backward moved.