DFSK K 2019 Series, Service Manual

Page 1: ...2019 DFSK Extended Cab Truck Service Manual...

Page 2: ...Contents Identification of the vehicle 1 Identification of Number 2 VIN 3 Serial Number of the Engine Main Technical Parameter A Parameter of Mini Bus 1 Engine Parameters 2 General Function Index 3 Fu...

Page 3: ...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 Paramete...

Page 4: ...ION OF THE VEHICLE 4 7 Tyre Air Pressure 8 Capacity Parameters 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 F...

Page 5: ...ontrol 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 1...

Page 6: ...x 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 Shift handlebar 32 Front...

Page 7: ...LE 7 1 Running in 2 Start of the engine 3 Safety driving 4 Brake 5 Economy driving environmental adaptability Guide for Vehicle Operation 1 Fuel 2 Generator strap 3 Compressor belt 4 Engine oil 5 Engi...

Page 8: ...ermostat 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 Steeri...

Page 9: ...THE VEHICLE 9 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 Op...

Page 10: ...e 1 Daily inspection 2 Regular check and maintenance 3 Regular maintenance period and items 4 Signs for maintenance 5 Maintenance Analyzing Eliminating the Malfunction 1 Malfunction of engine system 2...

Page 11: ...aw 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 Disposition of Emergency 1 Startin...

Page 12: ...IDENTIFICATION OF THE VEHICLE 12 Maintenance of the Vehicle 1 Cleanness of the vehicle inside vinyl plastics 2 Cleanup Wax of the Vehicle s Outer Part...

Page 13: ...IDENTIFICATION OF THE VEHICLE 13 I Identification of the Vehicle...

Page 14: ...e beam which is under the seat that beside the driver s and above the Meter Board and on the nameplate 2 VIN There are two VINs one is on the aluminum plate which is on the right front side of the Met...

Page 15: ...DENTIFICATION OF THE VEHICLE 3 Main Technical Parameter...

Page 16: ...icle 2 Common performance parameter Items Unit DFSK MINI BUS SPECIAL BUS EQ636 series EQ638 series EQ640 series EQ641 series EQ639 series EQ502 series Max Speed Km h 100 110 115 120 125 102 105 125 10...

Page 17: ...n L 100 km 6 2 6 5 Note As to the different practical condition the real fuel consumption will be a little higher than the value above 4 Main demension Items Unit DFSK MINI BUS SPECIAL BUS EQ636 serie...

Page 18: ...636 series EQ638 series EQ640 series EQ641 series EQ639 series EQ502 series Curb Weight kg 985 970 1000 1010 1015 1030 1050 1130 1145 1120 1100 1000 1015 1020 1030 Total Weight kg 1565 1400 1595 1610...

Page 19: ...SK MINI BUS MODELS EQ636 Series EQ638 Series EQ640 Series EQ641 Series EQ639 Series EQ502 Series Front tire Zero load kPa 200 165 70R14 155R13LT 200 175 80R14 200 165 70R14 155R13LT Full load kPa 240...

Page 20: ...5 3 Lubrication system of engine L 3 3 2 4 2 4 2 4 5 Fuel tank L 40 50 Only for EQ6390PF Series Lubrication oil of transmission box L 1 2 1 3 1 3 1 3 1 5 Lubrication oil of rear axle L 1 2 Braking oi...

Page 21: ...465 engine 900 50 474 engine A C water Temperature Protection 110 Engine water Temperature Protection 90 High Pressure Protection MPa 3 2 Low Pressure Protection MPa 0 2 Over heating Protection 150 5...

Page 22: ...Xseries 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 bo...

Page 23: ...Main Technical Parameter of the Complete Vehicle 11 B Parameter of Mini Truck...

Page 24: ...F Truck Double cabin EQ1021TF Widened truck EQ502 Van EQ502 Van EQ502 Special truck EQ1021GF24Q7 Truck Max Speed Km h 100 100 120 105 125 100 120 100 100 120 100 120 Gradeability 30 Braking distance w...

Page 25: ...tical condition the real fuel consumption will be a little higher than the value above 4 Main Dimension Item Unit DFSK truck and other special vehicle models EQ1020TF Truck EQ1021NF Truck Double cabin...

Page 26: ...1115 555 1150 580 Inner size of carriage mm 2700 2460 2290 1440 340 1390 1650 1900 1440 340 430 2800 1540 350 2460 2370 1650 1440 1430 1400 1350 1650 2310 2460 1330 1400 1440 340 430 940 5 Main weight...

Page 27: ...l vehicle models EQ1020T F Truck EQ1021NF Truck Double cabin EQ1021TF Widened truck EQ502 Van EQ502 Van EQ502 Special truck EQ1021GF24Q7 Truck Front tire Zero load kPa 200 165 70R14 155R13LT 200 185R1...

Page 28: ...udes EQ1021NF 1 4M 1 7M 2 0M EQ1021TF widened truck series includes EQ1021TF22QN11 2 9M EQ1021GF24Q7 Truck series includes EQ1021GF24Q7 2 3 2 5M EQ502 van series includes EQ5021XXYF EQ5024XXYF4 truck...

Page 29: ...Main Technical Parameter of the Complete Vehicle 17 Vehicle Devices Mechanics Operation...

Page 30: ...on shall be pressed down while the door is open and pull up the window then close the door Note The door shall be locked well and the locking button shall be pressed down while driving to avoid any un...

Page 31: ...2 is for use of the window in the driver s side Switch 3 is for use of the window in the co pilot s side Press down the button 4 then button 3 can not work press again then the button 3 is workable Pu...

Page 32: ...trol Middle row seat The middle row seat has two kinds moveable and folding Movable Seat Pull up the adjustor of the sliding rail and the seat can moved freely forward or backward while the seat moves...

Page 33: ...n push the lock tongue to the lock catch until hear the clatter sound The length adjustment of the saftety belt is very important While adjusting the lap belt please check the lock at the meantime to...

Page 34: ...ng compound grease spot chemical article especially storage battery sour liquid polluted While washing you can use neutral soap and water If the safety belt is worn and torn polluted or damaged should...

Page 35: ...ter 2 Wiper Syringe Switch 3 Lighting Turning and high low beam converting switch 4 Head lamp control switch 5 Rear Foglam 6 Rear Foglam 7 Cigarette Lighter 8 Auxiliary Frame Air Bag 9 Side Intake 10...

Page 36: ...g time unless the engine is running or else the battery will discharge Note The working time for starter shall not exceed 5 seconds If the engine cannot be started please wait at least five to ten sec...

Page 37: ...a low but stable speed HIGH Run in a high but stable speed OFF Stop gear Pull the control pole back will lead to spray clean lotion Note When the lotion stops should the control pole be loosen when th...

Page 38: ...alled to rear wind window Press the wiper switch on the dash board one time the rear wind window wiper starts to work Press the wiper switch another time the rear wind window wiper stops 13 Horn The h...

Page 39: ...all the four turning lights and sideway turning lights will flash at the same time And press the other side of the button will stop this When the vehicle is in an emergency or abnormal condition use...

Page 40: ...ight Turn the headlight switch to the second gear and press the foglight switch the foglight will be turned on and so will the indicator light press again the foglight is turned off so is the indicato...

Page 41: ...Vehicle Devicesxs and Mechanics Operation 21 Windshield defrosting air door The central vent hole The side defrost vent hole The broad vent hole...

Page 42: ...ntrol the circulation of the air of inside outside Tempreture control button Control the tempreture of cold warm air blue is cold air and red is warm air Draft Control Button Control the rotate speed...

Page 43: ...tion of the air of inside outside Tempreture control button Control the tempreture of cold warm air blue is cold air and red is warm air Draft Control Button Control the rotate speed of fan that is ad...

Page 44: ...light Fuel Gauge Return Button for Odomet indicating instrument Water Thermometer Function Indicator Light Speedometer The speedometer expresses with km h the speed of the automobile Odometer The odo...

Page 45: ...e normal scope that is between C H When the pointer moves to H direction and exceeds the scope it means the engine too hot you should stop the vehicle Fuel Gauge While the pointer at the F position it...

Page 46: ...ing caculation count again since 0 analogize sequentially to count for the first time The short odometer has four figures to show the speed 18 Assembled Meter In the short range of milage the last fig...

Page 47: ...driving the water tempreture should be kept in the normal scope that is between C H When the pointer moves to H direction and exceeds the scope it means the engine too hot you should stop the vehicle...

Page 48: ...el of the bottom shell of the engine passes low or the lubricating system breaks down please make the engine go out and carry on the oil level check and annotate immediately If fail to fix a breakdown...

Page 49: ...low speed if you believe it is safe for do so Otherwise please trailer it to the maintenance stop 18 Assembled Meter When the ignition switch puts through this indicator light will be on and will be...

Page 50: ...arts or lights in the course of running it shows the engine control module breaks down please ask Dongfeng YUAN Maintainer for help 19 Cigar Lighter Press the cigarette lighter button wait several sec...

Page 51: ...Key 3 Wave Band Tuning Knobs 4 Balance Control Knobs 5 Tune Control Button 6 Hour Setting Key 7 Minute Setting Key 21 MP3 Radio One and half of cabin The picture is just for reference 1 MUTE 2 On Off...

Page 52: ...Mirror Regard the inner mirror and inner rear view mirror as a combination and it is set up in the middle of the top of wind window Inner view mirror can rotate from side to side up and down along cen...

Page 53: ...er rear view mirror according to your demands making that you can see the behind vehicles or other objects through it And the surface of the outer rear view mirror is protruding surface While judging...

Page 54: ...he top of the brake rod with thumb and then put back the brake rod in the normal position Note Parking brake rod should be drawn up totally otherwise it is unable to prevent wheel from rotating when p...

Page 55: ...gear push backwards in the central position 5th gear pull towards right first and then push backward Reverse gear pull towards left 32 Front Storehouse Cover The handle of front storehouse lies below...

Page 56: ...Vehicle Devicesxs and Mechanics Operation 36 Operation of the Vehicle...

Page 57: ...5Km h Gear 2 25Km h Gear 3 40Km h Gear 4 60Km h Gear 5 75Km h 2 Start of the Engine Before the Start of Engine Make sure the brake has been locked up Make sure the joy stick of the derailler is in the...

Page 58: ...slowly when step on the clutch listen to the voice of the engine with the gradual release of the clutch the engine voice will change then step on throttle and let go of clutch pedal gradually 3 Safety...

Page 59: ...o drive a vehicle Avoid Emergency Brake it is a waste of energy for braking and also recovering driving speed will consume the fuel Keep the invariable speed Keep the invariable speed in the allowed r...

Page 60: ...he speed should be limited below 50KM H while driving with tyre chain Driving on the ramp road of mountain area While climbing change the gear to a low gear promptly according to the slope and the rot...

Page 61: ...Guide for Vehicle Operation 41...

Page 62: ...Guide for Vehicle Operation 42 Guide for Vehicle Operation...

Page 63: ...the generator when the strength of the belt reaches above mentioned criterion 3 While changing the strap unscrew and make the generator slip and move inwards Tighten the strap according to the regulat...

Page 64: ...7 Thermostat 8 Transmission Oil Gear oil of 85W 90 GL 5 Refer to the service maintainance instruction manual of the gaslion machine of DELPHI system or unite electricity systematic electricjet serial...

Page 65: ...nance instruction manual of the electric jet series engine of DELPHI system or unite electricity system for the dismantlement clearance and fixing of the Air Cleaner 11 Spark Plug The spark plug is F6...

Page 66: ...hing out device 13 Throttle Valve Block 14 Three way convertor The exhaust system of the electricity jet is equipped with three way convertor to deal with aftertreatment Note While installing the spar...

Page 67: ...17 Clutch Pedal The free way of the clutch is 15 25mm and it is improper for longer or shorter which should be adjusted 18 ABS ABS Antilock Braking System ABS for short can prevent wheel from braking...

Page 68: ...ment the brake oil the trademark for it is JG3 Brake System When stepping the brake pedal down completely the distance A between the pedal and the front wall shall not less than 95mm And it should be...

Page 69: ...and the middle of the tire will be badly worn and torn The air pressure of the tire should be checked by the pressure gage 20 Tyre Note When pumping the tyre pls slowly pump the tyre and at the same...

Page 70: ...be carried out counter clockwise to make sure its fastness 21 Battery The battery electrolyte level should always be between lines of upper and lower if the electrolyte is lower than lower add the ele...

Page 71: ...using the aluminum foil or aluminum wire and other substitutions are not allowed If the fuse is burnt in a very short time it shows there are big problems with the electric please go to Dongfeng Mini...

Page 72: ...b Push forward the rear fixing foot after breaking off relations take out box cover backward you can lift off bulb for change See the picture use an opener and wrap it with cloth then pr down the glas...

Page 73: ...Check Maintenance Service 53...

Page 74: ...please go to Dongfeng YUAN Auto Maintainance Station for help Note Please prevent the ECU from water while in rainy day or while washing 25 ECU Don t electrification is it dial ECU plug to insert is...

Page 75: ...ople 28 Extinguisher The usal and operation of Extinguisher Take out the extinguisher and pull the cover then spurt extinguishing agent in 1 5M distance of root of fire Pressure extinguisher valve unt...

Page 76: ...t of room when turn over to behind and insert the ring of limited location then put double bolt into double groove hole with bolt ring of limited location and check equipment correct or not Open lift...

Page 77: ...that makes latch hook rotate at the same time and makes latch hook get rid of box rear plate hinge then realizes box rear plate open automatically When cargo box in normal location rear plate can not...

Page 78: ...dumping nobody is allowed to stand on the cargo box Notice the vehicle could not exceed 10km h when the cargo box is fully lowered to the original position Notice No flammable explosive or sticky mat...

Page 79: ...professional must not operate No forcible operations are allowed to the cargo box External lubricating spot 1 ball joint of the hydraulic cylinder 2 joint of frame ball joint and the stand ball joint...

Page 80: ...ned to prevent impurities mixing into oil and affected 3 Storage and use fuel containers and tools must be clean to prevent oil contamination 4 The oil is mainly used in steel steel pairs of hydraulic...

Page 81: ...meters and months will be the standard maintenance time The check adjustment lubricant and other maintenance service should be strictly subject to the stipulated time in the form Make form recommend s...

Page 82: ...1 Fan Water Pump Compressor Drive Branch Belt Strain Abrasion G G G G 2 Camshfte Synchronization Tooth Belt Strain abrasion damage J T G J T G J T G J T G 3 Valve Gap J T J T J T J T 4 Engine Bolt cyl...

Page 83: ...oft Pipe Tie in J T G J T G J T G J T G 17 Fuel Steam Storing Device J T G J T G J T G J T G 18 PCV Valve J T G J T G J T G J T G Periods Items Km 100 0 10 20 30 40 50 60 70 80 monthes 6 12 18 24 30 3...

Page 84: ...ke Drum Brake Shoes J T G J T G J T G J T G J T G J T G J T G J T G 26 Brake Soft Pipe Pipeline Leakage damage J T G J T G J T G J T G J T G J T G J T G J T G 27 Tire Abnormal Abrasion Abnormal Air Pr...

Page 85: ...Elasiticity X X X X 30 Steering Wheel Gap Elasiticity J T G J T G J T G J T G J T G J T G J T G J T G 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 33 Compressor J...

Page 86: ...ting Device 1 2 Failure of the Spark Plug 1 3 Joint of High Voltage Damping Wire Loose or being Damaged 1 4 Damage of Ignition Coil Replace Repair or Replace Repair or Replace Replace 2 Failure of Fue...

Page 87: ...Replace Reliable Connect Decrease lack of the Engine Power 1 Malfunction of Ignition System 1 1 Inprope Spark Plug Gap or Burnt 1 2 Poor Connect Damage of High Voltage Damping Wire 2 Malfunction of Fu...

Page 88: ...or Burnt Spark Plug Gap 2 2 breakoff or creepage of High Voltage Damping Wire Adjust or Replace Replace or Connect 3 Lack of Crock Pressure As mentioned above 4 Others 4 1 Connect Flex or Breakoff of...

Page 89: ...ormance of Water Pump 6 Too Much Begrime in Cylinder Body AND Cylinder Cover 7 Block or Leakage of Radiator 8 Incorrect Engine Oil Kind 9 Block of Engine Oil Cleaner or trap valve 10 Insufficient of E...

Page 90: ...ion of Piton Ring Cylinder 2 4 Piston Ring not Stagger as regulated 2 5 Abrasion of Valve Oil Seal 2 6 Abrasion of Valve Rod 2 7 Damage of Cylinder Washer 2 8 Breakoff of Rocker arm Screw Clean of San...

Page 91: ...wheel Surface Diaphragm Spring Weak Clutch Cable Rust Adjust the Free Stroke Replace Clutch Flake Replace Clutch Flake Clutch Compressive Board or Flywheel Replace Clutxch Cover Replace Cable Hard Sep...

Page 92: ...or Replace Input Shaft Bearing Guard Ring Replace Clutch Flake Replace Clutch Flake Replace Clutch Flake Replace Clutch Cover or Flywheel Screw Down Again or Replace fixing Washer Clutch Sounding Abra...

Page 93: ...Spring Weakened or the Spring Broken Deformation of Gearshift Axle or Gearshift Fork Replace Replace Gearshift Troubled Incorrect Clutch Pedal Stroke Deformation or Break of the Cluch Friction Disc D...

Page 94: ...ntial Gear or Driving Gear Replace Oil Re infuse Replace Oil or Infuse Adjust Adjust or Replace Replace or Screw Down Again Replace Bearing Noise Gear Oil going bad or including water Insufficient Gea...

Page 95: ...ace the Spring Replace the Tyre Check Adjust the Front Wheel Alignment Repair Brake Screw Down or Replace the Suspension Abnormal Abrasion or over Abrasion of Tire Sagging or Damage of Spring Imbalanc...

Page 96: ...flexible Banace the wheel or replace the tire and or wheel Replace the wheel bearing Replace the end of turning sidelong coulping bar Front suspension arm Repair or replace wheel and or tire Replace...

Page 97: ...or return Turning Jamming of turning sidelong coupling bar end Jamming of Global Joint Jamming of Steering Volume Poor Lubricant of Rack Pinion Maladjustment of Front Wheel Alignment Improper Adjustme...

Page 98: ...nt Repair or Replace Replace Screw Down Bolt Replace Bush Screw Down Wheel Nut Screw Down the Bolt or Nut Replace Wheel Bearing Replace Spring Infuse Lubricant or Replace Strut Bearing Replace Sway wh...

Page 99: ...k Absorber or Strut Suspension suppressed to the bottom deflexion or shaking while body truning overload failure of shock absorber or support spring shows failure or drooping stabilizer bar loose fail...

Page 100: ...or ground connctoion failure change fuse check short circuit check circuit condition change monitor repair when necessary output temperature is wrong control dragline crack or winding air damper damag...

Page 101: ...heck and regulate AC idling check AC thermistor check AC water temperature sensor check high and low voltage switch check top AC relay check accelerate cut switch repair as needed check AC amplifier c...

Page 102: ...drive belt is slipping electronmagnetism clutch is wrong check cryogen condition check system leak check freezing machine check evaparation check AC thermostor resistance check AC controler check expa...

Page 103: ...k the expansion valve Change the fluid airer refill the cryogen Check the failure of the disconnection switch of high speed Check the AC controller Check the electromagnetic clutch Check the compresso...

Page 104: ...ck the cryogen Check the evaporator Check the thermistor of AC Cool air not strong Jam in the evaporator Leak in the cooling device or the pipe Failure of the motor of air blower Failure of the circui...

Page 105: ...Replace Replace Inadequate cool air The gasket is damaged The leaf valve fails Replace Replace No rotation The rotary valve is blocked causing the jam of the cylinder and or the axle The electromagnet...

Page 106: ...r Brake pad block linings wear Brake Cylinder Damage Brake caliper assembly failure If fitted LSPV improper adjustment of sensor length of the spring The system with air Damage to the sensor spring LS...

Page 107: ...Repair or replacement Required adjustment Should use the same axis the same tire tread Check the hose to soften the tubing is damaged with new brake hoses and a new double decker steel replacement Ch...

Page 108: ...st rear brake Replacement brake shoe Replacement brake shoe Brake Back bit delay the release of the pedal the brake pedal can not go back in time in situ Master cylinder piston can not return the corr...

Page 109: ...or loose floor mounting bolts Repair or replacement Replacement Replacement Replace or tighten the mounting bolts After starting the engine brake warning light Implementation of the brake the brake wa...

Page 110: ...tance of ABS sensors between terminal connectors are in the 1 4 1 8K range at 20 C 68 F environment Proceed to step 2 Replace ABS wheel speed sensor assembly 2 1 Disconnect the ignition switch 2 Disco...

Page 111: ...xists a foreign body to see if it is in good working condition Proceed to step 5 Cleaning repair or replace 5 Visual ABS wheel speed sensor mounting holes front wheel or remove rear drum rear wheel an...

Page 112: ...eck the ABS hydraulic unit solenoid valve terminal if it is connected correctly 3 If correct then under this section hydraulic device the solenoid valve check to check the contents of the resistor and...

Page 113: ...switch 2 Connect the connectors to the ABS hydraulic unit 3 Measure the ground resistance of module terminal A1 A2 A7 A8 B12 or B13 to see if it s connected With a well known ABS control module repla...

Page 114: ...re not bright Bulb damage Faulty headlight switch Headlights left and right are blown fuse Faulty wire or ground Check that the lamp Check the headlight switch Check the fuses left and right if necess...

Page 115: ...ground connection doesn t work Check lamp Repair line The failure of turn signal and emergency warning light Problem Reason Treatment Flash frequency is too high or only one side Flash Doesn t flash...

Page 116: ...braking Stop brake is not released Short of brake liquid brake pipe leaking Circuit problems with the brake warning light Trouble with ABS if there is brake pipe leaking Short of brake liquid Release...

Page 117: ...rgency Measurement 97 ABS warning light will be on while starting the engine if it has Trouble with ABS Please see ABS ABS warning light will be on while braking if it has Trouble with ABS Please see...

Page 118: ...em Not Work In a situation that the headlight is opened try to turn thee ignition switch to START position in order to confirm the storage battery state If headlight becomes too dark or goes out total...

Page 119: ...Make the two vehicles close to each other but not touch each other while using the storage battery on the other vehicle Connect the two ends of the first cable with the anode of the corresponding bat...

Page 120: ...ater pipe junction if position of letting out is found it is forbidden to use the engine before getting rid of the trouble c If no leaking is found you can infuse coolant to store liquid barrel and th...

Page 121: ...t wheel faces just in the front The steering wheel is locked up firmly by special lock framework If you use the front traction euippment to tow from the front part the rear wheel shall be fixed to a m...

Page 122: ...Vehicle Protection 102 Maintenance of the Vehicle...

Page 123: ...Part The dirt or any other things on the paint will cause the following problems as time goes on Cover paint Fades The degradate lacquer film causes the car body to get rusty The scratch of the body...

Page 124: ...he paint layer should be repaired immediately do not make metal exposed to the air for a long time b The moisture content dust silt under the mat of the auto room can accelerate the corrosion of the v...