Zhejiang Xinyang XY300 User manual

300 Utility Vehicle
Operating instruction

2
Table of contents
(First revision in 2007)
If this specification is reviewed, please forgive we will not notice.
INotices
IITechnical parameters
IIIPlacement drawing for whole vehicle
IVInspection before driving
VDriving operation
VIRunning-in of new vehicle
VIIMaintenance and repair
VIIITrouble diagnosis and elimination
IXScrewing moment of important bolts
XSpecification and dosage table for fuel, Lubricating oil and brake liquid
XICircuit diagram

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INotes
1. Please read this operating instruction carefully before using this vehicle, and
drive, check and repair it by the requirement in this manual to keep vehicle at good
technical status and prolong its using lifetime.
2. Initial running for 1000km of vehicle is period. In this period, it is necessary
to accord with the regulation of period(see the chapter—for new vehicle). After period
expires, it is necessary to make vehicle maintenance by regulation.
3. Quality warrant term of vehicle: in normal using situation, it is three months
or 3000km mileage after buying this vehicle, if one of these two exceeds regulated
value, quality warrant term expires. In quality warrant term, for those malfunctions
caused by design, manufacture, assembly quality which influence your usage, our
company will repair them freely.
4. Damaged parts in following items could not be repaired freely, they should
be paid, please forgive:
(1) Damages caused by wrong usage, maintenance and storage which do not
accord with this operating instruction.
(2) Damages caused by force majeure, chemical substance, bad substance or
other natural disasters.
(3) Consumed parts in normal usage, such as: bulbs, fuse(pipe), air filter core,
engine oil filter core, gasoline filter core, brake friction sheet(drum), spark plug, tyre,
transmission belt, appliqué, rubber parts, standard fastening parts, lubricating
oil(grease), brake liquid and so on.
(4) Damages caused by improper assembly or repair, such as self-dismantling or
changing this vehicle without approval of our company and chartered sale(repair)
store, or sending chartered sale(repair) store for repair which is not appointed by our
company.
(5) Vehicles which could not provide warrant card or vehicle purchase credential.
(6) Malfunctions caused by using other parts or accessories which are not
provided by our company.
(7) Various overhead expenses caused by repairing vehicle(such as telephone fee,
vehicle fare, freightage, work missing fee, repair fee out of repair store appointed by
our company).
(8) Abnormal abrasions and damages caused by wrong using gasoline,
lubricating oil and brake liquid.
(9) Feeling phenomenon which could not influence mechanical performance,
such as: noise, vibration, heat and so on.
(10) Damages caused by that you do not check and maintain vehicle periodically
by our requirements.
IITechnical parameters

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(I)Common technical data
1Mass parameters(kg)
Mass of whole equipments(not including driver)540Kg
Front shaft240Kg
Rear shaft300Kg
2Dimension parameter(mm)
Total lengthtotal widthtotal height:263012301890
Minimal clearance apart from ground183
Wheelbase1800
Treadfront wheel1058 rear wheel1070
Approach angle(°)60
Removed angle(°)85
(II)Using data
1High running speed(km/h)53
2Small steering semi-diameter(m)3.7
3Brake performance (No-load brake distance m)
When V

=20km/h2.5
When V

=30km/h5.4
When V

=40km/h9.5
When V

=50km/h14.6
40—50Km/h accelerating timeS15
4Oil consumption for 100 kilometers (L)6when speed is 40km/h
5Exhaust
Reach Euro II exhaust standard.
6Limit load of good box300Kg
(III)Engine
TypeVM173MN
Form four-stroke water coolingsingle cylinder horizontal typeroof valve
Carburetor type.
Cylinder diameter(mm)72.75
Travel(mm)66.8
Cylinder volume(mL)278
Compressed ratio101
Exhaust quantity of engine(mL)278
Maximal power (kw/r/min)16/6500
Maximal torque(N·m/r/min)23/5500
Rated power (kw/r/min)13.8/6500
Lowest fuel consuming rate (g/Kw·h)340

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Idling speed (r/min)1500±10%
Ignition typeTCIdigital
Start typeelectronic start
Fuel categoryRQ-93 lead-free gasoline
Lubricating oil categorySAE 15W—40
Engraved position of factory numberUpper surface on rear part of left
crankcase
Ignition ahead angle(°/r/min)10/1500
32/1500
Lubricating typePressure and splash lubricating type
Engine oil pump typetrochoid type
Water pump typecentrifugal type
Carburetor typeY28V5
Magnetoelectrical machine typeTCI exterior spring flywheel magnetoelectrical
machinePower supply voltage 12V
Spark plug typeDR8EANGK
Clutch typedry typeautomatic centrifugal type
Automatic shift ratio2.20~0.88 1
(IV)Chassis
1. Clutch and transmissiontapered plate belt transmission, stepless shift
2. Reverse gear device of main transmission
Main transmissionTapered arc gear transmissiontransmission rate
38/12
Reverse gear deviceforward and back transmission rate 11
3. Driving type42 rear wheel drive; shaft transmission
4. Suspension
Front suspensionswing arm type independent suspension.
Rear suspensionwhole type rear axleabsorber type non-independent
suspension
5. Wheel alignment parameter
Front wheel camber2°±45
Main pin
K.P.I 13°
Main pin castor 4±1°
Front toe-in 2—5mm
6. Tyre
Front wheelFront wheel type 258.00—12 Air charging pressure
250Kpa
Rear wheelTyre type 2510.00—12 Air charging pressure

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300Kpa
7. Steering organization
Adopt gear rack type redirector, transmission rate: 181;total circle
number of steering plate3.75total swing angle of steering wheel75°
8. Arrester
Running arrester adopts front and rear placement dual-pipeline hydraulic
pressure brake system, front and rear wheels adopt drum type arrester. And parking
arrester adopts mechanical transmission organization to work on rear wheels.
9. Goods box overturn roofand self-saving winch
Good box could adopt overturn roof structure and equip self-saving winch
to drag itself if relapsing into loose sludge.
(V)Electric apparatuses
1. Pipeline systempipeline system adopts single-line systemMinus ground
strappipeline voltage is 12V
2. Generatortype is FM169rated power is 300W
3. Storage cellvoltage is 12Vcapacity is 24A·h
4. Starting engine type12V forever magnetic DC electric engine

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IIIPlacement drawing for whole vehicle
1Engine hood 2Indicator 3Front headlight
4Bump 5Front tyre 6Seats
7Safety Belt 8Side board 9Fuel tankcap
10Rear fender 11Goods box 12Reinforce pole
13Head Rest 14Top cover 15Steering Wheel
16Frame

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Side drawing for engine
1CTV case 2Oil intake of gear case 3Flange of transmission shaft
4Generator 5Carburetor 6Starter
7Idling speed electromagnetic valve 8Spark plug
9Oil intake of engine

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VIN code position Engine and rear suspension
Oil intake of engine Engine oil dipstick
Oil drain plug of engineunder the engineIntake of gear case
Fuel box cover (on the left side board) Coolant & brake fluid intake
Warning Engine oil quantity should be between upper and lower position, over more or
less oil would burn out or damage engine.
Warning Oil drain plug of engine should be tightened

otherwise engine would burned
for oil leakage.

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Oil checking hole of main reducer
MP3 player and spare switch Oil intake of reverse gear device
WarningOil in main reducer should be filled by prescriptive trademark.
Oil quantity in main reducer should equal to oil intake orifice ,over more will
incur oil leakage, and over less will burn out main reducer.
Warning

Oil quantity in reverse gear should be added by regulation, much more will incur
reverse gear leaks oil, while much less will incur reverse gear is burned.
Warningit is very dangerous to unscrew radiator when engine is hotfor steam
and water will spurt by the pressure to hurt people at this time. It is necessary to
unscrew radiator cover after engine becomes cool.
Warning: Please fill up the brake liquid according to the stipulated trademark and
type. Can not mix the different brake liquid from different makers. Keep the
liquid level in proper position, otherwise will cause accident.

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IVcheck before drive
1 Check the leakage contain of engine,such as oilcooling fluidfuellube and so
on should have no leakage.
2Check the height of engine oil, brake liquid and cooling liquid, if necessary, add
some.
3Check the air pressure in tyre.
4. Check the function of safety belt.
5. Check whether steering transmission organization has been loosened.
6. Check whether engine bracket, bolts, and bolts of transmission system and running
system have loosened or fallen off.
7. When starting engine, listen and check whether there is any abnormal noise, and
observe whether each instrument is normal.
8. Check whether steering is flexible and reliable; check brake free travel
function(including parking brake).
9. Check whether lighting system (steering light, brake light, warning light, small
light, dipped headlight, high beam and so on) is complete and effective.
10. Check whether vehicle box overturn roof and self-saving winch could work
normally.
11. Check fuel quantity.
Warningit is necessary to tie safety belt before driving.
Driver should buy person safety insurance
Driver should control speed and try his best to keep vehicle run at economical
speed
Driver should control speed strictly by the size of swerve(the highest speed
could not exceed 20Km/h).
For safety, the speed must be controlled within 20km/h when turn round.
Better do not load the goods higher than case. If so , please tie the goods.
The exhaust pipe might make big noise when rotation speed of engine reaches
to 7500r/min. At this time some abnormal phenomenon will occur, like engine
rotation speed unstable, decreasing power, rotation speed of engine decreased.
Meanwhile the more fuel consumed and more smoke discharged. This is because
the function of speed limiter, and it is normal. Please limit the speed within
50km/h when driving.
The anti-freezer is filled in UTV when finishing the installation. But it is only
can be driving in condition upper -15. The suitable anti-freezer should be used if
the environment temperature is cold than -15.

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VDriving operation
1. Safety driving notes for farmer vehicle
To guarantee your driving safe, please accord with following items
—Tie safety belt—
Safety belt could avoid you are thrown out of vehicle when happening sudden
swerve and accidents, and guarantee running safe effectively.
—Inspection before driving —
Careful inspection before driving is necessary to guarantee running safe and enjoy
driving pleasure.
—Be familiar with your farmer vehicle—
Your driving technique and mechanical common sense are base of safety driving.
We advise you practice driving on open location before driving on road.
—Accord with highway code —
According with highway code will guarantee your running safe furthest.
—It is necessary to keep aware when driving in rain—
Rain weather will drop the brake performance and operation performance of your
farmer vehicle, and bring bad influence for your running safe, so it is necessary to
note.
2. Operation
Key
Keys for this vehicle have two kinds that are ignition switch key and oil box
key, each has two, one of them should be preserved carefully for spare.
Ignition switch
Ignition switch has four positions
“OFF”closepositionAll circuits except instrument, brake light and
loudspeaker locate turnoff status.
“ON”openpositionAll circuits except engine are connected, and they
could start at any moment or make engine keep running status 
“START”startpositionConnect engine and ignition circuit, and start
engine. Handle returns to “ON” position automatically after engine starts
“LOCK”lockpositionAll circuits are cut off, and steering wheel is
locked after pulling out the key (key could be pulled out only at this
position).
Waring: It could not turn ignition to “LOCK” position and pull out key before vehicle is
parked stably. To prevent steering wheel from losing control.

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Meter
 Speedometer 4show running speedfor its structure, it will show
running speed when stepping down accelerator pedal on neutral
position.
 Odometer 8show accumulated running total mileagesfor its
structure, it will show accumulated running total mileages when
stepping down accelerator pedal on neutral position.
 High beam indicating light 7When high beam of headlight is
lightened, high beam indicating light will lighten.
 Indicating light 2, 5When steering lights to left and right are
lightened, corresponding steering indicating lights on instrument will
flash. When warning light is lightened, left and right steering
indicating light will flash at the same time.
 Fuel level meter 6show fuel quantity.
 Thermometer 1show the temperature of coolant of engine.
gRotation speed meter 7: show the rotation speed of engine.
hGear position display 3, & 2WD and 4WD exchange display 9: no
display on this model.
 Main switch of lamplight
 When ignition switch is at “ON” position and lamplight main switch is
turned to “ ”position, front and rear small light are lightened.

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 When ignition switch is at “ON” position and lamplight main switch is
turned to “ ”position, front headlight and rear small light are
lightened.
 When ignition switch is at “ON” position and lamplight main switch is
turned to “ ”position, press down lamplight main switch handle,
headlight changes to far light from close light; raise lamplight main
switch handle, headlight changes to close light from far light;
 When ignition switch is at “ON” position and lamplight main switch is
at “OFF” position, raise lamplight main switch handle(feeling elastic),
high beam illumines, and high beam extinguishes after releasing the
handle.
 When ignition switch is at “ON” position, press the red button switch
at the front of combination switch cover, warning light will flash; and
pull out button switch, warning light will extinguish.
 When ignition switch is at “ON” position, turn lamplight main switch
handle anticlockwise, left steering light will flash; and turn lamplight
main switch handle clockwise, right steering light will flash.
 When ignition switch is at “ON” or “OFF” position, step down brake
pedal, brake light will illumine.
 Loudspeaker button

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Press down loudspeaker button on steering wheel (anyone of these two),
loudspeaker will hoot.
 Accelerator pedal and brake pedal
At the front of driver’s right foot, the left is brake pedal, farmer vehicle will
start or accelerate by stepping it when shift handle is at “D” position or “R”
position.
 Parking brake handle
When pulling up parking brake handle, rear wheels will produce brake force
to prevent vehicle from sliding when vehicle is parked.
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WarningIt is necessary to strain parking brake handle when vehicle is parked to
prevent sliding; and it is necessary to press down the front button of parking brake
to drop handle down when running; it could not use parking brake when running
arrester is used(except emergency).

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
Good box overturn roof and self-saving winch
When it is necessary to over turn cargo box to discharge good, at first, open the
rear door of cargo box, then open towing and turn main switch to ?O@position,
and press down?UP@on ?TRAILER@conversion switch on the upside of
instrument, at this time, cargo box will over turn backwards; and return will stop
after relinquishing; while press down DOWNon ?TRAILER@conversion
switch on the upside of instrument, cargo box will drop, and return will stop after
relinquishing.
When farmer vehicle stuck into the muddy area and could not run out, you
could make self-saving measure by front fixity or piling. At this time, open the
drag hoof of towing rope, and turn towing and overturn main switch to ?O@
position, then press down ?IN@position and ?OUT@position on ?WINCH@
conversion switch on the upside of instrument, at this time, winch steel wire rope
will “shrink” and “expand”; return will stop after relinquishing.
Cigarette lighter
The cigarette lighter installed on vehicle and also can be used as mobile
phone charger or other small electric units’ power. 


Windshield WiperOptional
 There are 2 speeds “low” and “high” when turn the switch clockwise. Turn
anticlockwise is “Stop”. 
Warning: When cargo box overturn or winch self-saving work has ended, it is
necessary to turn towing and overturn main switch to ?OFF@switch to avoid
wasting electricity and incurring unnecessary loss.
Note: This inlet is 12V DC. Please check the voltage which is suitable for your units.


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



VIRunning-in of new vehicle
Cooperation between the surfaces of each part of new vehicle is locating
adjusting and running-in phase, for surface friction of each part is big, the result of
running-in quality influences greatly using lifetime of farmer vehicle. In running-in
period, please implement strictly the regulation about speed limit, load limit and
periodic maintenance to reduce
1. Highest speed:
Running mileage Highest limit speed
Initial 800Km 30Km/h
800A1600Km 40Km/h
Exceed 1600Km 50Km/h
2. Accelerate and decelerate
It is necessary to avoid sudden and frequent acceleration and deceleration
and keep running in even speed in running-in period.
3. Heating engine before running
In running-in period, it is necessary to run at idling speed for 3-5 minutes
after starting engine to pre-heat engine, then start running after lubricating oil
flows on each friction surface.
4. Note engine cooling
In running-in period, it is necessary to note water temperature in engine to
avoid running in low temperature for long time and in high temperature
without water, this will strengthen abrasion and drag cylinder.
5. Check the loosing situation on each linking part of all bolts usually
For fastening bolts on each part of new vehicle are easy to loosen, it is
necessary to note the fixed situation of each bolt, especially the bolts of

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transmission organization and fixed equipment.
6. First maintenance of vehicle
In running-in period, after running for 1000km, it is necessary to complete
first maintenance, maintenance details could refer to “Maintenance and
repair”.
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VIIMaintenance and repair
1First maintenance item table
Sequence
number
Category Checking item Adjusting content
1 Engine Change engine oil and oil
filter
Adjust idling speed 
1500±10% listen whether
there is any abnormal
noise in engine; clean air
filter core
2 Brake Front and rear wheel brake;
parking brake; brake
performance
Brake liquid height 
Brake pedal free travel
20A30mmTravel of
parking arrester is 2A3
gears
3 Steering
organization
Operate flexibly without any
block phenomenon
Fastening bolts on
redirector and steering
transmission organization
which could influence
safety performance
4 Transmission
box
Stepless shift performance
and belt abrasion
5 Tyre Tyre pressure and thread
depth
Check front tie-in2A
7mm
WarningFirst maintenance is necessary to implement best performance of
farmer vehicle, prolong using lifetime and insure safe.

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6 Transmission
organization
Whether the bolts, flange
nuts on transmission shaft
and the bolts on main driver
are tightened.
7 Lamplight Illumination and signal Every kind of lamplights,
signal switches and
buttons, etc
8 Battery Liquid height in storage
cell(except the
maintenance-free battery)
Liquid surface should be
between upper and lower
limit marked, it is
necessary to note only
distilled water could be
filled in storage cell
9 Mwter Display is normal and correct
10 Dump bed
and
self-saving
winch
Work normally
2Routine maintenance item table (checked by consumer)
Sequence
number
Category Checking item Adjusting content
1 Engine Engine oil level; leakage
situation, cooling water level
Oil level is between
upper and lower limit;
engine oil, cooling
liquid, fuel and other
mediums do not have
any leakage; clean
empty filter periodically
2 Steering
organization
Operate flexibly without any
block phenomenon
Each linking drag pole,
ball head and locking
nut are tightened.
3 Brake Brake liquid height; brake
pedal travel and free travel;

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brake performance
4 Tyre Air pressure, thread, crack
and wound
Tyre air pressurefront
wheel 0.25Mparear
wheel 0.3Mpa
Thread depth no less
than 1.6mm
5 Lamplight Illumination, signal and
loudspeaker
Every kind of
lamplights, signal
switches and buttons,
etc
6 Battery Liquid height in storage
cell(except the
maintenance-free battery)
Liquid surface should be
between upper and
lower limit marked, it is
necessary to note only
distilled water could be
filled in storage cell
7 Instrument Display is normal and correct
8 Dump Bed
and
self-saving
winch
Work normally
9 Transmission
organization
Each bolt of transmission
organization has not been
loosened.
Periodic maintenance item table for farmer vehicle
Checking Kilometers
term
Checking
Item month
First 1000Km
first 3 months
Every
3000Km
Every 3
months
Every 6000Km
Every 3months
Brake soft pipe Check Check —
Change once every three years