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.

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1.4 Safety Belt
Safety belt wearing (As show in picture)
Drawing the safety belt lock, pass the
should strap through shoulder, the belt
crosses the pelvis ,then press the lock into
the lock stand until hears “clicking” sound,
press down the red button on the lock
stand, the safety belt then will be unlocked. As show in picture:
Drawing the safety belt on the shoulder upward through the tongue, the shoulder slanting belt can
be adjust freely, the urgent locking mechanism of the safety
belt will suddenly stop or deadlocks during the impact.
Safety belt checking (As show in picture)
Regularly check the parts including braid, lock catch, lock,
rolling-up, fixed point and guide ring, replace the damaged
safety belt and the one cannot work appropriately.
Warning

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The driver and the passenger have to wear safety belt when the
vehicle is travelling. The safety belt provides front part collision
protection. The driver and the passenger seat at the front-row have to
wear the safety belt during travelling to avoid injury from crashing or
the fatal accident occurrence.
The passenger is not allowed to seat in the cargo area, otherwise,
once the accident occurs; they might get a more serious injury than
the one who has fasten the safety belt at the seat.
The lower part of the safety belt should pass the pelvis, do not fasten
in the waist, the shoulder strip should fasten on the shoulder, do not
slip into the arm.
The safety belt cannot be twisted when wearing it, tightened comfortably with request. If the safety
belt is loose, the person will not be able to obtain the safe protection.
Make sure the safety belt lock catch inserts in the corresponding lock.
Do not fasten the safety belt on the clothes pocket with hard pieces or fragile, otherwise, when the
accident occurs, you may get injured from the goods fastened under the safety belt.
Regularly check the attrition and damage of the safety belt, it should be replaced if it is over wears

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or damaged. After serious crash, should replace the used safety belt even it has no obvious
damage.
All safety belts after collision should be replaced (only if the accident is extremely small), even do
not looks obvious. If the unused safety belt does not satisfy the operation requirement or damaged,
it also should get replaced.
The safety belt should not get polluted from oil, chemical substance, especially the accumulator
electrolyte, may use moderate soap and clear water to clean the safety belt.
In order to prevent mobile relaxation when use the safety belt adjusting mechanism, the user is not
allowed to change or to add mechanism to the safety belt device.
1.5 The control device on the steering column
(1) Lighting Switch
The lighting switch has 4 positions (As show in picture)
LOCK
This is the normal parking position; the key can only take out in this
position. The ignition deadlocks once the key is take out.
ACC

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When the key turns to this position, the radio and cassette player and the attached facility power are
connected, but the engine has no power.
ON
When the key turns to this position, all power in the vehicle are connected, the engine is at the start-up
condition.
START
When the key turns to this position, the engine starts, release the key, it will return to “ON” position
automatically.
Warning
Do not take out the key when the vehicle is moving, do not leave the child in the vehicle alone, and
remember to take the key. Without anybody’s looking after, the child is possible to cause the vehicle
move and causes injure.
Do not give the start-up motor to operate more than 5s for one start-up. If the engine does not work
and has not started, wait for 10s and starts again. If it does not work after several times, then check
the fuel and the ignition system.
Do not leave the key at the “ON” position if the engine is not turning, otherwise the storage battery

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will be discharged.
(2) Combined Switch
The combined switch is located underneath the steering wheel (As show in picture), the left and
right multi-function control handle controls the front signal light, headlight, headlight variable light,
left and right steering light through different motion mode. The function of various marks on the
combined switch and the multi-function control handle are as follows:

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Left Control Handle
This control stick is under the left side of the steering column, the operation is as follows:
(a) Revolving the handle at the end of the left control stick to turn on or turn off the light. There are 3
control positions on the handle: all lights are disconnected at “OFF” position; front position light, tail
light, plate light and meter light are connected at position, the headlight is not connected.
All above lights and headlight are connected at position.
When the headlight turns on, down press the control stick to transform into upper beam, up lift to the
middle position then transforms to low beam. When the upper beam connects, the upper beam
indicator on the meter will be connected. Up lift the control stick, the headlight will become the
variable light (returns when releases)。
(b)Steering Signal
Forward and backward moving control stick may connect to the left and right steering signal.
Turn right the forward push control stick, and turn left the backward pull control stick.
Right Control Handle

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The control stick is at the right hand side of the steering column, it has 4 gears.
INT: The windshield wiper is the gap gear; the gear is extremely suitable for fog and light rain
weather.
LO: The windshield wiper operates in a stable low speed.
HIGH: The windshield wiper operates in a stable high speed.
OFF: The windshield wiper will stop operating if it does not work.
Upward lifts the control stick, spray the cleaning liquid, it restored immediately when releases, the
cleaning liquid spraying stops.
Warning
In the cold weather that the windshield is freezing, it should connect to the defroster device before
use the windshield wiper.
Do not use the cooler anti-freezing fluid as the windshield cleaning fluid, such may affect the vision
seriously, and will possibly damage the coating of the vehicle.
In order to prevent damaging the windshield wiper and the clean system part, please pay attention
to the following matters:
1. Do not attempt to use the windshield wiper for dust removal on the dry windshield, otherwise it

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will scratch the windshield, and damage the windshield wiper piece. Use cleaning liquid to
moist windshield before use the windshield wiper, when the cleaning liquid does not blowout,
do not continue to run the windshield wiper, otherwise it will damage the wiper motor.
2. In winter, clean the ice and snow on the arm of the wiper before use the windshield wiper.
3. Check the windshield wiper system carefully before travelling, especially in bad weather.
4. When add the cleaning liquid, only add to 3/4 of the liquid storage tank volume in order to
ensure there has enough expansion space at the low freezing temperature when cleaning.
5. Use the qualified cleaning liquid that conforms to the stipulation.
(3) Horn
The horn button is located on the steering
wheel. When the power is connected, press
the horn button, the alarm rings.
1.6 Dashboard and Various Switches
(1) Holder (2) right control handle
(3)Combined dashboard (4) emergency
flashlight switch (5) left control handle (6)

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other switches (7) radio and cassette player (8) central vent (9) heater switch (10) front cover
plate switch (11) ignition switch (12) lighter (13) ashtray (14) tool box
(1) Combined dashboard, speedometer, odometer
The speedometer expresses the speed of the vehicle by
Km/h
The odometer shows the total travel distance, the
smallest unit is 1Km.
Fuel Gauge
The fuel gauge shows the oil mass in the oil tank, when
the indicator at “F”, diesel is full in the oil tank. At position “E”, the oil tank has no diesel.
Water Temperature Gauge
Indicate engine coolant temperature. During travelling, the coolant temperature should maintain at
the normal range, the indicator moves towards “H” (high temperature) from “C”. If it surpasses the
scope of “H”, the engine is over heat, and then stops the vehicle immediately.
Left and Right Steering Indicator

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When the ignition switch is connected to the steering switch at the connecting position,
indicator flashes, the steering light is also lightens, means it also gives the steering signal.
Left turns, the left indicator flashes; when right turns, right indicator flashes.
Headlight Upper Beam Indicator
The headlight uses upper beam, indicator lightens.
Warning Indicator
Emergency flashlight: press the emergency flashlight switch when emergency case occurs,
emergent stopping, send out the warning light to avoid crashing with the coming vehicles,
indicator flashes.
Warning Do not use this switch unless the emergency case occurs.
Oil Pressure Indicator
When the ignition switch is connected, indicator lightens immediately, after the engine is