2019 Extended Cab Truck

- Service Manual -
 Content
1. Vehicle Identification ...................................................................................................... 1

2. Main Technical Parameter of the Complete VehicleError! Bookmark not defined.

3. Vehicle Devices & Operation.................................... Error! Bookmark not defined.0
4. Usage of the Vehicle ......................................................................................................... 29
5. Vehicle Operation Manual ........................................................................................... 35
6. Checkout & Maintenance Service .......................... Error! Bookmark not defined.
7. Malfunction Analyse & Elimination...................................................................... 57
8. Disposition of Emergency............................................. Error! Bookmark not defined.
9. Maintenance of the Vehicle ......................................... Error! Bookmark not defined.
 Vehicle Identification

1. Vehicle Identification

1
 车辆标识
side of the frame beam which is on the body which is under the front
1. Identification Number under the seat that beside the row right side seat.
driver’s, and above the Meter Board
EQ 1 02 1 GF24Q7
and on the nameplate
3. Serial Number of the

A B C D E 2. VIN Engine
The serial number of the Engine
A：Self-Stipulate Code Name
should be marked on the convexity
of the rear lower part of the right
B：Vehicle Catagory Number
cylinder.
C：Main Parameter Code

D：Serial Number of the Product

There are two VINs, one is on the
E：Self-Stipulate Code Name aluminum plate which is on the right
front side of the meter, the other is
The VIN should be marked on the

2
 Main Technical Parameter of the Complete Vehicle

2. Main Technical Parameter of the

Complete Vehicle

3
 Main Technical Parameter of the Complete Vehicle
1. Parameter of the Engine

Please see the instruction manual of engine along with the vehicle

2. General Performance Index

Optional Engines of EQ1021GF24Q7

Items Unit
BG13-20 AF10-06
BG10-01 DK12-01
/EQ474i /EQ465i-21

Max. Speed km/h 135 110 120 130

Gradibility % 33.1 25.4/24.6 27.9 42.3

Brake Distance at 50km/h(full
loading)
MinmumTurning Diameter
≤20
m Any part of the vehicle shall not exceed the width of the trial driveway,
that is 2.5 M.
m 10.3

3. Fuel Ecomomy

Items Unit Optional Engines of EQ1021GF24Q7

BG13-20 AF10-06 BG10-01 DK12-01
4
 Main Technical Parameter of the Complete Vehicle
/EQ474i /EQ465i-21

* Fuel Consumption per 100 km L/100

5.3 4.9/5.2 5.1 5.1
(60km/h) km

* Note: The real fuel consumption will be higher than this numerical value for different use conditions.

4. Main Dimensions
Items Unit Vlalue

Total Length mm 4280±20

Total Width mm 1560±10

Total Height(Unladen) mm 1880±15(W/O Guardrail 1850±15)

Wheel Space mm 2760±15

Front Track mm 1310

Rear Track mm 1310

5
 Main Technical Parameter of the Complete Vehicle

Front Overhang mm 580±10

Rear Overhang mm 940±10

5. Main Quality Parameter

Optional Engines of EQ1021GF24Q7
Items Unit BG13-20 AF10-06
BG10-01 DK12-01
/EQ474i /EQ465i-21

Kerb Weight kg 940 930 930 940

Gross Weight kg 1665 1655 1655 1665

Passenger/ Rating Loading

Pax/kg 2（Include drive）/595
Capacity

6. Toe-in Parameter
Optional Engines for EQ1021GF24Q7
Item Unit BG13-20 AF10-06
BG10-01 DK12-01
/EQ474i /EQ465i-21
Toe-in mm 0.108(0～5)

6
 Main Technical Parameter of the Complete Vehicle
7. Tire Pressure

Optional Engines for EQ1021GF24Q7

Item Unit BG13-20/AF10-06/BG10-01/DK12-01/EQ474i /EQ465i-21

Optional Tire for EQ1021GF24Q7
165/70R14 165R13LT 155R13LT

Unladen kPa 180 200 200

Front Tire
Fully Loaded kPa 220 240 240
Unladen kPa 200 220 220
Rear Tire
Fully Loaded kPa 250 300 375

8. Capacity Data

Optional Engines of EQ1021GF24Q7

Items Unit
BG13-20 AF10-06
BG10-01 DK12-01
/EQ474i /EQ465i-21

Cooling System of Engine L 5.5 4.5 4.5 5.5

7
 Main Technical Parameter of the Complete Vehicle
Lubricating System of
L 4.2～4.5 3.2 3.2 3
Engine

Fuel Tank L 40

Lubricating Oil of Gear-Box L 1.3～1.5 1.3 1.3 1.3±0.15

Rear axle lubricating oil L 1.2

Brake Fluid L 0.6

9. Cooling System Data

Optional Engines of EQ1021GF24Q7

Item Unit
BG13-20 AF10-06
BG10-01 DK12-01
/EQ474i /EQ465i-211

Capacity of Refrigerating W 7200 5350 7200

8
 Main Technical Parameter of the Complete Vehicle

Wind Speed while Refrigerating M3/h ≥400

W(Nc2000r/
Consumption Power of the Compressor 3430 2610 3430
min)
Automatic Increase of
r/min 1100±50
Idle Speed
A/C Water Tempreture
℃ 110
Protection
Control Engine Water
℃ 90
Parameters Tempreture Protection
High Pressure Protection MPa 3.2
Low Pressure Protection MPa 0.2
Overheating Protection ℃ 150±5

9
 Vehicle Devices & Operation

3. Vehicle Devices & Operation

10

1. Front Door
① Inside of the Vehicle
All the doors can be locked by pressing
down the locked button. After that, one
cannot open the door either inside or
outside the vehicle. When open, pull the
locked button upward.
The front door can be opened or locked
by keys. While open, the locked button
up; while locking, the locked button
down.
Vehicle Devices & Operation
② Inside of the Vehicle
All the doors can be locked by pressing
down the locked button. After that, one
cannot open the door either inside or
outside the vehicle. When open, pull the
locked button out.
The front door can be opened or locked
by keys. While open, the locked button
out; while locking, the locked button
press down.
Note:
Press down the locked button while the
vehicle running ，the door should be
locked safely to prevent the door
opening accidently.
2. Keys
This vehicle equipped with two keys,
please keep one in a safe place for spare
use.This key can be used for ignition
switch, front door and fuel cover.
Note:
Please keep the key along with you at
any time.
3. Rocking window outfit by
11

hand
There are two kinds of rocking window
outfit: by hand and by electric.
When by hand, there is handlebar on the
inner side of the door. Turn the
handlebar clockwise
counter-clockwise, the door window
will come up or come down.
4. Rocking window outfit by
electric
Vehicle Devices & Operation
When by electric, there is a button on
the inner side of the door.
Button One: Electrical Riser Button on
the driver’s side to control
the door window of the
or
copilot.
Button Two: Riser Button for door
window on the side of the
driver.
Button Three: Electrical Riser Button on
side of Copilot.
Pull the button up, the door window will
be closed, press the button down, the
door window will be open.
12

5. Seat
Front Row Seat
The fixing of the front row seat is just
like the picture below, make the two
pothooks hook the button, and then
fasten it.
Adjustment of the front row seat: Pull
the sliding adjusting handlebar which is
under the seat up, the seat will slide to
Vehicle Devices & Operation
the required position; pull the backrest
adjusting handlebar beside the seat, the
backrest will turing automatically, then
loose the handlebar, the backrest will be
fixed in the position. And the backrest
can be folded forward.
Note:
Do not adjust the driver’s seat while
driving, otherwise, the seat may move
forward or backword abruptly which
may cause driver lose its control.
The safety belt of the front row seat is
6. Safety Belt automatic contraction.While using,
please pull out the lock tongue which
connect the safety belt and wing your
body and pass, then push the lock
13

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 make sure that it has been
locked, and then pull up the shoulder
belt till the lap belt being buckled tightly.
The length of the safety belt can be
adjusted freely according to different
requirements.While undo the safety 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.
Note:
While driving, please wear the safety
belt.
Vehicle Devices & Operation
The safety belt is designed according to
the structure human body skeleton, (See
the picture). Please note that, the waise
band part shall not be across the
abdomen.
The adjustment of the safety belt is not
only reliable and comfortable but also
can help to make safer. Flexible safety
belt will influence its protection
function.
Safety belt should be prevented from
polishing 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 be
changed.
It is very important that when the safety
belt impacted fiercely, though it is not
obvious, it should be changed.
Do not use the deformed saferty belt.
One safety belt is only for one person,
tie the children on knee of passenger to
the safety bealt is very dangerous.
The position of lock limit position
should not interfere or block the safety
belt fully withdraw.
14
 Vehicle Devices & Operation
7.仪表板 Meter Board 6. Rear Foglam
7. Cigarette Lighter
8. Auxiliary Frame Air Bag
9. Side Intake
10. Centre Intake
11. A/C Switch
12. Switch Assy Defroster
13. Rear fog Switch
14. Fog Switch
15. Emergency Switch
16. Tool Box
1. Assembled Meter 17. Control Board for Heating
2. Wiper & Syringe Switch 18. Ignition Switch
3. Lighting/Turning and high/low beam converting switch
4. Head lamp control switch
5. Rear Foglam

15

8. Ignition Switch
1. ‘Off’: the auxiliary equipments
don’t work, only head lamp and horn
work, and the key can be pull out only
in this position.
2. ‘ACC’: assisitant equipments
(radio & cigar lighter) work and the
engine don’t work.
3. ‘On’: while at this position,
all 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
Vehicle Devices & Operation
in’ON’position for a long 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 seconds, and try again. If the
engine fail to start after several times,
please check the fuel power supply ① Lighting Switch: there are three
system or pay a visit to the
Maintanence Stop of Dongfeng Sokon places, ‘off’means all lights being
Vehicle. turned off; ‘ ’means front small
9. Lighting, Turning and lights, tail lamp, liscence lamp and
light for meter being turned on;
High/Low Beam Control Pole
‘ ’means the headlights being
turned on.
16

② Turning signal light switch:
While the ignition key is in the
position in “ON ", it can send off
signal by turning control lever forward
and backward. Pull the control lever
forward from the middle position and
then the right turning light glitter; pull
the control lever backward and then
the left turning light flickers. The
control lever gets back to the middle
position automatically after turning.
③ Far, near light button: Put the light
switch in “headlight " position.
Pressing down is the far light, getting
back to middle position is the near
light, and lifting the control lever up,
Vehicle Devices & Operation
the headlight glimmers (overtake).
10. Wiper & Cleanser
Control Pole
The control lever is on the right of the
steering wheel, and the control lever
has four gears:
INT：Wiper is the intermission gear,
which is suitable for fogy and rainy
day.
LO: The wiper will run at stable and
low speed.
HIGH: Wiper will run at a stable
high speed.
OFF: Wiper will stop running.
Pull back the control lever, it can jet
cleaning liquid.
Note:
When the cleanser stop spraying,
should release control lever, turn on
the washing device switch when have
no cleaning liquid, then the electric
machine will be damaged. If attempt
to remove the dust on the dry
windscreen glass with the wiper,
windscreen glass and wiper will be
damaged. You should drench the
windscreen glass with the cleanser
first, and then open the wiper.
Note:
In windscreen glass frozen cold
weather, you should remove ice and
snow of the arm first, make the defrost
17

device to put through, and then use the
shave.
11. Horn
Wherever the ignition switch is, when
you press the horn button, it can
sound.
The horn button is on the steering
wheel:
① The horn button is in the centre of
the the three widths steering wheel.
② The horn button is on the side of
the square width steering wheel
Vehicle Devices & Operation
12. Emergency Switch
Press down the button, all the four
turning lights and the side turning
lights glitter simultaneously. Press the
other end will turn off the lights.
This switch is only used for
emergency situation and running in
abnormal situation.
13. Foglight Switch
Front Foglight:
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 indicator light.
Rear Foglight
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 indicator light.
18
 Vehicle Devices & Operation
14. Heating System

The heating system to provide heating, defrosting and ventilation funvtion.

① Windshield defrosting air door ③ The side defrost vent hole

② The central vent hole ④ The broad vent hole

19
 Vehicle Devices & Operation
④ Defrost & Warm Air circulation so as to avoid the air in the
15. Control Board of Heating vehicle too dirty and the windpane
Warm air is sent off from the exhaust
port on the floor, some is sent off from will become humidity and with low
System thickness oxygen.
the defrost exthaust port of windscreen
and side defrost exhaust port. 16. Assembled Meter
⑤ Defrost
⑥ Cycle Control Button of
Inside & Outside
Control the circulation of the air of
inside & outside.
① The wind is sent off through ⑦ Tempreture control button
the intake in the centre of the the Control the tempreture of cold &
warm air (blue is cold air, and red is
meter board or through side
warm air) （The picture is just for reference）
ventilation.
⑧ Draft Control Button ① Speedometer
② Sending off air in both Control the rotate speed of fan, that is, ② Left & Right turning
directions: Cold air is sent off from the adjust the draft.
indicator light
centre intake, and the warm air is sent ⑨ Optional Button for
③ Fuel Gauge
off from the bottom intake. Ventilate Position
④ Return Button for Odomet
③ Warm Air Note:
The time for blowing should not be ⑤ Indicating instrument
Warm air is sent off from the exhaust
port on the floor. too long while the air is in inner ⑥ Water Thermometer
20

⑦ Function Indicator Light
Speedometer
The speedometer expresses with km/h
the speed of the automobile.
Odometer
The odometer has six -figure number
in all to show the total driving mileage,
the minimum unit of mileage is 1km.
Vehicle Devices & Operation
Odometer after finishing caculation , exceeds the scope, it means the engine
count again since " 0 " , analogize too hot, you should stop the vehicle.
sequentially to count for the first time. Fuel Gauge
Note:
Pay attention to the running mileage,
and maintain the vehicle according to
this instruction manual..
Water Thermometer
While the pointer at the ‘F’position, it
shows that the fuel tank is full of fuel;
while at the position of ‘E’, it shows
the fuel tank is empty
Left & Right turning
indicator light
While driving, the water tempreture
should be kept in the normal scope,
that is: between ‘C’& ‘H’. When the
pointer moves to ‘H’direction and
21

When the ignition switch is on the
position of turn-on, making the
turning switch gets through, the
indicator light will flicker and the
turning light turns on showing turning
signal given. Turning left, the left
indicator light turns on; turning right,
the right indicator light turns on.
High beam indicator light
Vehicle Devices & Operation
When every headlight adopts high
beam or dipped headlight, this
indicator light will be on.
Sump, pressure, indicator
light
When putting ignition switch through,
this indicator lamp lights immediately,
after the engine is started, it will go
out immediately. Otherwise it shows
the oil level 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 yet, please
go on an all-round way checking of
lubricating system or get in touch.with
the local distributors or Dongfeng
Sokon Maintenance Department.
Charge Indicator Light
When ignition switch puts through,
this indicator lamp lights immediately,
22

and engine goes out immediately after
starting. Otherwise it shows the
battery charge system breaking down,
please check if the fan belt ruptures or
relaxes at first, if normal, carry on
circuit check again or get in
touch.with the distributor or Dongfeng
Sokon Maintenance Department.
Safety Belt Indicator Light
When the ignition switch puts through,
this indicator light will be on and will
be out after the safety button inserting
into the safety belt fixing housing
which shows the safety belt has been
well buttoned.
Brake, Liquid, Position
Vehicle Devices & Operation
Indicator Light
In normal cases, when the ignition
switch in ‘ON’ or " START "
position, the light is on , and it will go
out after the engine starts.when the
liquid level of the container of brake
liquid is lower than the fixed liquid
level, the light will be on. And it will
be out after adding brake liquid
according to the regulation.
Note:
It shows the brake system breaks
down when the ignition switch is on
the position of ‘ON’or ‘START’ but
the indicator light is not on or it is not
out after the engine starts or the
indicator puts through abnormally
while driving. If on these cases, please
ask the Dongfeng Sokon
Maintenance Department for help.
When the indicator light puts through
abnormally, please bear the vehicle off
the road and test the brake system on
the roadside.
Note:
At this situation, it necessary to need
longer parking distance, more
powerful pedal force and longer pedal
stroke.
After test, please drive the vehicle to
the nearest maintenance stop at low
speed if you believe it is safe for do
so. Otherwise please trailer it to the
maintenance stop.
Engine, Trouble, Indicator
Light
23

When the ignition switch is in the
position of ‘ON’, the trouble lamp will
be on, it shows the the trouble lamp
circuit is normal.
After the engine is started, the trouble
indicator lamp will go out, if the
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 Sokon Maintainer for
help.
17. Cigar Lighter
Vehicle Devices & Operation
cigarette ash, push it downwards, then
totally pull out from the socket
outwards. Push the ash box along the
guide while putting.
Note:
The cigarette end should be put into
the ash box after putting it out so as
not to cause fire.
Press the cigarette lighter button, wait 19. MP3 & Radio
several seconds and the resistance
wire will turn red and hot, and it can
be taken out to use after it
automatically rebounds to its original
position.
18. Cigarette Ash Box
（The picture is just for reference）
（1）MUTE
（2）On-Off/ Sound Effect Knob
The ash box can be used after being (3) Number Button
pulled out, while clearing up the (4) Clock Set Button
24
 Vehicle Devices & Operation
(5) FM Button
(6) AM Button
（7）SET Button
(8) USB Button
（9）AUX Button
Tool box by hand undraw handle may
（10）AS/PS Knob be unlock tool box ， interior
（11）AUX placement a little thing.
（12）USB 21. Interior Light & Inner
(13) Screen
Rear View Mirror
20. TOOL BOX
The indoor light button consists of
three pieces of shelf location.
“OFF" is closed.
“DOOR “means switch at the door,
when the button is in this shelf, the
light is not on while closing the door,
and the light is on while opening the
door. As any door is closed
uncompletely, this light will not go
out.
“ON” means being turned on, while at
25

this shelf, the inside light will be on.
Look at the light inside and regard
mirror as succeeding in all inside, 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 central axle;
and park it at the any position inside.
22. Outer rear-view Mirror
Vehicle Devices & Operation
Adjust the outer 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.
Note:
While judging by the vehicle or other
objects through the protruding lens,
please pay attention that the articles
will be much smaller and farther than
seeing through the flat mirror.
23. Sunshading Board
The sunshading board can rotate up
and down by winding its pivot. While
adjusting, place hands close to both
ends of the mount ing pad and rotate.
There is a small mirror on the back of
sunshading board which is on one side
of co-pilot.
24. Safe Handgrip
Safe handgrip is located on the upper
side of each seat (The driver’s side
doesn’t have.)
Note:
While in the course of running, the
passenger should hold the handgrip
tightly.
Do not hang anything on the handgrip
26

to prevent it from influencing the
driver’s line of sight which may cause
accident.
25. Tool Kit
Vehicle Devices & Operation
⑤ Triangle Warning Plate
⑥ Spanner for Tyre
○
7 Clip
The tools shown ①②③④⑤⑥ in
the picture are one for each. Please
refer to Chapter 5 ‘Instruction for
using Jack’ to check the placement
of the jack and jack crank.
26. Brake Rod by hand
27. Pedal
Note:
Parking brake rod should be
drawn up totally, otherwise it is
unable to prevent wheel from
rotating, when parking in the
extremely cold weather, please
put the shelf in the low-grade or
reverse grade, live in the wheel
with cushion headblock.

Draw up the brake rod, the vehicle

will stop; when release the stopping
brake, pull the brake rod a little up and Clutch Pedal
① Fire extinguisher push the button on the top of the brake
Clutch pedal can break transmission of
② Jack rod with thumb and then put back the
engine and wheel. Step down the
③ Crank of Jack brake rod in the normal position.
footboard, the engine power
④ Driver’s tool assembly disconnects, loose footboard, power
27

recover.
Note:
Do not put your foot on the clutch
pedal in the course of driving for
frequent use will cause the over
abrasion of the clutch.
Brake Pedal
It makes four wheels apply the brake
by steping on the brake pedal.
Environmental condition such as cold,
humidity, ice and snow etc. will cause
the brake shriek, it is normal, if the
brake screams in every brake or
shrieks loudly, please check the brake
system.
Vehicle Devices & Operation
28. Hood
Accelerator Pedal
The rotating speed is controlled by
accelerator pedal, step down the
accelerator pedal, the rotating speed of
the engine will increase and the output
power will go up.
Shift Handlebar
The handle of front storehouse lies
Note:
below left of the instrument board of
Do not change the gearlever from 5th
gear into reverse gear. Please first the driver's cabin. Before opening,
push the gearlever to neutral and then please pull the handle outwards and
change into reverse gear. then the handle up to open the front
st
1 gear: first pull towards to left and cover, then prop up storehouse cover
then push forward.
with struts.
2nd gear: first pull towards to left and
then pull backward 29. Light & Signal
3rd gear: push forwards in the central Requirements
position
Note：
4th gear: push backwards in the central
The user is allowed to external
position
lighting and signal device after
5th gear: pull towards right first and
refitting.nor with mandatory standard
then push backward
external lighting and signal device
Reverse gear: pull towards left。
28
 Usage of the Vehicle

4. Usage of the Vehicle

29
 Usage of the Vehicle
2. Do not exceed the running-in Note:
1. Running-in speed limit value listed in the table Once the engine starts, please
below. release the ignition key to
The frist
3. While in the course of running-in, disconnect the starter, otherwise, it
Gear 2500
please make the number of the may cause the starting system to be
Kilometer
passenger not exceed 4. damaged. Do not try to sart the
Gear 1 10km/h 4. After starting, do not make the engine once for more than five
Gear 2 20km/h engine run idle at high speed, please seconds, if it fails to start, please
Max
pre-heating the engine. try again ten seconds later (let the
Recommended Gear 3 35km/h
Speed 2. Start of the Engine battery supply electricity). After the
Gear 4 55km/h
cold engine is started, don't make
Gear 5 65km/h the engine run idle at high speed.
Before Start of Engine
In the course of car running-in, we
use the best material, every part is Start the Engine
① Make sure the parking brake
processed meticulously, but before ① While turning the ignition switch
has been unlocked.
letting the engine bear peak load, to “START ", you can start the
each operating should pass ② Make sure the joy stick of the
engine. The electric jet system can
running-in stage. The initial derailler is in the position of neutral.
maintenance and running-in of the offer suitable blending gas mixed by
Note:
engine have close relationship with oil and gas and ignition advanced
Before starting the engine, hold the
its future performance and angle, so it is unnecessary to step on
hand brake to unlock and the
dependability quality, the general
gearlever should be in the position the throttle under any circumstance.
principle that should be followed is
of neutral.
as follows: ② If you can't start engine while
1. The running-in mileage is 3. Safety Driving trying several times, the engine
2500KM.
30

might happen with “flood the jar
“which cause the short circuit of the
spark plug. On this situation, please
completely step down the throttle
pedal and try again to start the
engine (then the ECU will control
fuel injector cutting off oil supply).
Five seconds later, the high-speed air
current blow down the overflow oil
and then let go of gas pedal and can
restart the engine at this moment.
③ If ECU has been cut out (such as
change the battery, ECU, and ECU
will not power off while parking),
when starting, please turn the key to
" ON ", if failed, please wait for five
to ten seconds or wait fifteen
seconds after starting, the curb idling
will be normal, and then repeat the
above course. Please check at first
whether there are vehicles coming
here and then step on the clutch to
have a try, then put into the low-gear,
Usage of the Vehicle
if it is difficult, please step on the
clutch to try again, after putting to
gear, let go of brake pole, meanwhile,
step on throttle 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.
When driving the vehicle, don't
regard the footboard as a stop for a
rest, or don't half step on clutch
while parking at the slope which
may damage the clutch.
While driving the vehicle, drivers
should frequently observe the
instrument and indicator lamp, and
do not step on the gas before the
engine do not reach normal working
temperature (80 degrees Centigrade
- 90 degrees Centigrade), otherwise
will shorten the life-span of the
engine and hinder changing the gear
steadily. The drive is along with
synchronization test machine which
make the gearshift easy and without
noise. A good gearshift would enable
rotational speed of the engine remain
throughout in a certain range, and no
matter how the speed change, you
can both save the fuel and lengthen
the life-span of the car by achieving
this.
4. Brake
The braking distance of the vehicle
increases with that of the speed of
vehicle, while applying the brake,
you should guarantee that there is
enough distance for the vehicle to
get to the brake parking point in
order to decelerate gradually.
Step on down brake pedal, the front
and rear brake will work at the same
time. If there are shrieks some times
while braking, it is because of
humidity of the road surface or cold
and snow weather etc. So it is
normal.
Note:
If there are always shrieks while
braking, please go to the Service
31

Station of Dongfeng Sokon.
Don't apply the brake in succession
for a long time, or put the foot on the
brake pedal while running for a rest
which will cause the brake to lose
efficiency for overheating or the
braking distance too long or will
cause the permanent damage of the
brake.
Note:
After water enters the brake drum, it
will make the brake lose efficiency
or its performance cannot be
predicable. So after the vehicle
paddles or being washed, you should
lightly step on the brake pedal
intermissively at a much low speed,
operate the brake repeatedly, and
dehumidify brake until resuming
normal efficiency of braking. Please
clean the brake after such road
surface as the deep mud ground,
sand ground, etc., try to avoid
wearing and tearing excessivly.
The vehicle is equipped with
Usage of the Vehicle
vacuum booster system; it can make time: If you don’t drive the vehicle
the brake more stable. Do not step
after waiting more than one minute,
on the brake pedal to-and-fro while
applying the brake. When the you should stop the engine. While
vacuum booster system lose starting the cold engine, you should
efficiency, the energy stored will operate idly until the indicator of the
gradually subside effort in brake
pedal with applying the brake each thermometer reaches “C " position ,
time. then begin to drive the vehicle.
Note: ② Avoid Emergency Brake: it is a
Without the vacuum booster system,
waste of energy for braking and also
it will need bigger footforce while
applying the brake and perhaps the recovering driving speed will
braking distance will be longer. consume the fuel.
③ Keep the invariable speed: Keep
5. Economy Driving &
the invariable speed in the allowed
Environmental road and traffic condition.
④ Keep the loading capacity
Adaptability
minimum limit
Economy Driving ⑤ Keep the correct tire pressure:
The following items will help you to when the tire pressure is
lower the fuel consumption: insufficiency, the resistance of the
① Avoid running idle for a long
driving will increase which may
32

cause the waste of the fuel, then the
tire should be pumped according to
the pressure indicated on the plate of
the the driver’s side door.
Note:
Please don't slide with neutral when
going, because vehicles with electric
jet system have the function of
gearing down and cutting off oil
supply which can guarantee the
economy driving. And the engine
keeps working at idle speed while
running with neutral; it will still
consume the fuel instead of saving
fuel.
5. Environmental
Adaptability
Driving on the icy road
You can use the tire tyre chain in
order to prevent the tire sliding on
the icy road.
Step on the brake pedal repeatedly
and steadily and evenly while
Usage of the Vehicle
applying the brake, instead of
stepping on the brake pedal suddenly
to prevent the brake wheels from
locking.
Start, accelerate or when driving a
vehicle, please keep invariable speed
to prevent wheel from turning round
and round or skidding which may
cause the vehicle sideslip.
Avoid the operation of the steering
wheelby turning fast or at large
angle. Decrease to the safe speed
and slowly change direction.
If the friction is increased by
equipping with tyre chain, please
pay attention to following points:
① Assemble the vehicle according
to the Instruction Manual of the
manufacturer.
② The 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 rotational speed of the
engine in case that the engine
overloads or being damaged. Pay
attention to following points while
driving on the ramp:
① The vehicle should be changed
into low gear while climbing the
slope in order to increase the engine
torsion.
Gearshift should be fast in case that
the engine stops working;
② Vehicle should be put into
low-gear at the downhill path, try to
brake the vehicle by taking
advantage of engine.
③ Don’t try to make the rotational
speed of the engine very high.
Note:
Do not step down the brake pedal for
too long time or step the brake pedal
for many times while in the course
33
 Usage of the Vehicle
of abrupt slope long slope, which
will cause the brake to lose its
braking ability for being overheated.

34
 Vehicle Operation Manual

5. Vehicle Operation Manual

35

1. Fuel
The oil shall be No. 93 high-quality
unleaded gas. The capacity of fuel
tank of this vehicle is 42 liters;
Refuel access cap lies in the right
below part of center pillar. Open up
the the cover by key and turn
counterclockwise, and then turn the
key clockwise to cover it tightly.
2. Generator Belt
Vehicle Operation Manual
While exerting the strength of about
98 Newton (strength of 10 kilograms)
to the adhesive tape of the fan
between the generator and fan, the
down quantity of new fan adhesive
tape is about 7-10 mm and the down
quantity of old fan adhesive tape is
10-15mm.
In addition, check whether the belt is
damaged, and method of adjusting
and changing of the belt are as
follows:
1. Unclamp the three setscrews of
the generator.
2. While wanting to stretch the strap,
unscrew and draw outwards the
generator, fix 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 regulation of 2 after
changing the strap.
3. Compressor Belt
The air-conditioned passenger car is
equipped with the compressor;
thumb down the strap accoding to
the regulation, there will be 6-9mm
sink and make sure that there isn’t
any damage. If the strap is needed to
be changed or adjusted, please send
it to the Maintanance Station for
repair.
4. Engine Oil
36

Engine Oil Trademark
Use 15W/40SP while the tempreture
is above 15°in summer; and use
10W/30SF (GB11121) while the
tempreture is below 15°in winter.
Note
Change the engine oil while the
running-in of the new gasoline
vehicle is 2500KM and after normal
driving for 5000KM.
Measurement and change of engine
oil, engine oil of level see DELPHI
system or unite electricity systematic
electricjet serial petrol machine use
and maintain the manual.
4. Engine Oil
Vehicle Operation Manual
Replacement of the Engine
Oil Filter
While changing the engine oil filter,
unscrew the engine oil strain;
Remove the engine oil filter by
turning counterclockwise, the clean
the engine installation surface with a
clean cloth; Spread some engine oil
around the rubber washer of the
engine oil strain and twist to new oil
strain with hand i until the oil strains
rubbers reach to the installing
surface.And then twist the strain
engine oil to 3/4 of the circles by
strain spanners.
5. Engine Strap
Note:
In order to make oil filter fasten
properlr, the more important thing is
to mark the position while the small
filter rubber washer meets the
installing surface and the oil filter
should not be screwed too tightly, if
the engine oil leaks from the filter
rubber washer, that shows the filter
is fixed unproperly or the washer
cover is damaged.
6. Coolant Trademark
Adopt the glycol water antifreeze.
Note:
The vehicles must be parking on the
plane ground while changing the
coolant.
Add, change and infuse
37

coolant
7. Thermostat
Note:
The time for warming up the
machine will be longer without
thermostat, and the machine piece
Vehicle Operation Manual
will be badly worn and torn while
working under low temperature
which will influence its service life.
8. Transmission Machine
Oil
Machine Oil for Transmission
Refer to the service maintainance
instruction manual of the gaslion
machine of DELPHI system or unite
electricity systematic electricjet
serial petrol machine use and
maintain the manual.
9. Gasoline Filter & Oil
Sulpply Tube & Oil Return
Tube
There is 0.3MPa in the oil supply
system. While changing gasoline
filter and oil supply tube and oil
return tube and tie-in, you should
adopt the right fittings from
Dongfeng Sokon.. You had better
go to Dongfeng Sokon. Auto
maintainance station, otherwise may
leave your car in hidden danger.
Note:
While changing the above fittings,
please pay attention to avoiding fire
caused by fuel jet.
10. Air Cleaner
The filter element of the air cleaner
should be often removed and washed.
Wash once when running 10000KM
38

on the pitch road, wash once each
time while running 2500 kilometers
at dirt road.
Refer to the service maintainance
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 F6TC (4C7T) and
the whorl is M14 *1.25. When there
is accumulated charcoal in the plug,
it is difficult to produce electric
spark. Remove the charcoal with the
wire or the needle, and adjust the
spark plug interval to 1.0-1.2mm.
Vehicle Operation Manual
The interval should be even and the
same on the electrode level of the
whole centre.
The spark plug whose pitch of screw
is incorrect in size is not to be used.
If the whorl is stretched out or
indentation while covering, it will
gather the charcoal powder in the
exposed whorl part. In this way, According to the situation of the
when dismantle the spark plug or imported vehicles euipped with
change with the correct spark gaoline spray system used in China
plugging will cause the damage of and the actual conditions of and
the whorl. petrol product which our country use
Note: at present, the vehicle, while parking
While fitting the spark plug, please for a long time, should start the
exert to screw it to prevent damage engine once every two or three
to the whorl, then screw it tightly by months and the time should be 2-3
spanner, the screw down moment is minutes so as to avoid knot glue of
25-30N.m. the petrol stop up the oil gushing out
device.
12. Oil Sprayer
13. Throttle Valve Block
39

Note:
Every performance index of air
throttle has been adjusted qualifiedly
already when the engine is
dispatched from the factory. The
user is not allowed to adjust the
adjusting screw of the throttle by
him, otherwise it will effect the
correctness of the data of the sensor
located in air throttle and then effect
the performance and exhaust of the
ehole vehicle. If there are some
troubles, please pay a visit to
Dongfeng Sokon.Auto Maintainance
Station.
14. Three-way Catalytic
Vehicle Operation Manual
Convertor
The exhaust system of the electricity
jet is equipped with three-way
convertor to deal with aftertreatment
of exhaust from engine; three-way
convertor can reduce the harmful gas
effectively.
It is quite easy for three-way
convertor to be overheated while the
gasolines engine working, and which
may cause the damage of the
three-way convertor. In order to
protect three-way convertor, while
the driver is in the course of
operating, please refer to instruction
& maintainance manual of gasoline
engine of DELPHI system or unite
electricity systematic electricjet
serial petrol machine use and
maintain the manual.
15. Electric Fuel Pump
The fuel pump is in the fuel tank.
Note:
Do not drive while the oil mass is
insufficiency, otherwise the fuel
pump will be burnt for the fuel has
been run out.
16. Turning Steering
Turn the steering wheel slowly from
left to right to check its idle stroke.
The idle stroke of steering wheel
along the circumference is 0-30mm.
The turning of the steering wheel
should be light and smooth and
40

without noise.
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,
abbreviate ABS), can prevent wheel
from braking completely suddenly
by automatically and repeatedly
adjusting the braking pressure. And
fully utilize peak value of the
adhesion coefficient among the tire
and ground and high lateral force
Vehicle Operation Manual
coefficient while applying the brake
promptly to gain the manipulation of
the automobile while applying the
brake and the direction stability, and
there is integrated control system of
electromechanics combined by
shortest braking distance advanced
electronictechnologyand mechanical
technology.
The work of ABS system is
automatic, no matter when, as long
as the apperceive wheel is locked up,
namely begin to work automatically.
Step on the brake pedal directly
while applying the brake, don't step
on the brake pedal repeatedly.
Note:
When the ABS loses its function, the
function of the braking system will
be the same as that of the common
braking system. And please use the
tire regulated by the instruction
manual.
Note:
To the same vehicle, when apply the
brake on some soft road surface
(such as the broken stone road
surface, snow road), the braking
distance of vehicle with ABS is
longer that that of vehuicle which
without ABS but with common
braking system. If the vehicle that
you drove with ABS system, please
reserve longer braking distance. On
decorating road surface, the braking
distance of vehicle with ordinary
braking system will be shorter than
that of vehicle with ABS.
41

19. Braking Oil Can
The braking oil can lies in left of the
outside of the front storehouse
clapboard. Check the braking oil can,
if the oil level is below the line of
‘min’, please complement braking
oil whose trade mark is JG3.
Note:
Do not mix the different kinds of
and different types of brake liquid
together, otherwise which may cause
the serious damage of the braking
Vehicle Operation Manual
system. Do not utilize the old, used
or unsealed brake liquid.
20. Braking System
Note:
Measure the space between the
brake pedals, the stool plate of the
wainscot and the rubber washer on
the pedal are not included.
When step the brake pedal down, the
distance ‘A’between the pedal and
the front wall shall not less than
95mm. And it should be checked and
maintained if the following things
happan while stepping on the brake
pedal by 294N (30kg):
① The braking force is insufficient.
② The braking is not stable.
③ The stroke for the pedals is too
big.
④ Brake blocked.
⑤ Brake with noise
⑥ The pedal bounced while
stepping on.
Hand Brake
Hold the handle brake rod upwards
to check if the rear wheel stopped ,
and check when draw the hand brake
rod upwards by strength of 20kg, if
the pole stops in (3-8) ratches.And
it shall also be checked that when
relax hand brake totally, there
should be no sense of being blocked.
21. Tyre
42
 Vehicle Operation Manual
loaded 2.4kg/cm2 3.75kg/cm2
165R13LT Please refer to P8

Note: Note:
The air pressure shall be measured While pumping the tire, please first
while it is the cold tire. slowly pumping the tire and
In order to prevent tire from being meanwhile check the tire pressure
worn and torn and lengthen its and stop pumping till it reachs to the
service life, please make the tires regulated value.
The tire trakemark of this vehicle is
165/70R14、165R13LT 、155R13LT, transposition when it is running The following check should be
and the pressure should be as every 10000km and adjust the air
carried out in the course of using:
follows: pressure of front and rear tire to the
regulated value (please refer to the ① Check the wearing and tearing
Tire pressure for 165/70R14 of the flower stria to make certain
pressure scutcheon on the driver’s
Loading Front Rear side door). that if it should be changed or not.
Wheel Wheel When the air pressure is too low, it
180kpa 200kpa ② Check if there are abnormal
Unladen will cause the tire worn and torn too
1.8kg/cm 2.0kg/cm2
2 wearing and tearing, crack and
much and difficult to drive and
Fully 220kpa 250kpa heavy fuel consumption; while the damage for the tire. If yes, please
loaded 2.2kg/cm 2.5kg/cm2
2
air pressure is too high, the vehicle change it.
Tire pressure for 155R13LT shakes badlly and cause the stability ③ Check if there are nail. Carpolite
Loading Front Rear bad and the middle of the tire will be
or other articles pierce into the tires
Wheel Wheel badly worn and torn.
The air pressure of the tire should be or embed in the flower stria.
200kpa 220kpa
Unladen ④ Check if the nut looses. While
2.0kg/cm 2.2kg/cm2
2 checked by the pressure gage.
Fully 240kpa 375kpa replacing the tire please use the
43

same type, same specification and
loading capacity tire as the original
tire. The flower stria for the four
changed tires should be the same.
Note:
While replacing the tires, the four
tires should be the same type.
Note:
The spare wheel shall be the yellow
steel wheel which can be only used
when emergency.
Taking the spare wheel as the formal
tire used for long time and long
distance is prohibited.
Vehicle Operation Manual
Replacement of the Tyre
① Take off the jack, tool and spare
tire from the vehicle.
② Loosen the tire, but do not
remove the nut.
③ Put the jack in a proper position
and raise it up.
④ Discharge the wheel.
⑤ Fix the wheel and change the
nut.
⑥ Lower the jack, fix the nut by
spanner.
The spare tire is put under the floor
of box of the vehicle, screw the
fixed screw on the vehicle
counter-clockwise and put down the
spare tire bracket, and remove it.
And the fixing and discharging
should be carried out
counter-clockwise to make sure its
fastness.
22. Battery
The battery electrolyte level should
always be between lines of ‘upper’
44

and ‘lower’, if the electrolyte is
lower than ‘lower’, add the
electrolyte to the marking line of
‘upper’. The loose of 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.
23. Fuse
There are two kinds of fuses, one is
the major fuse and the other kind is
the fuse in every part of circuit.
① Major Fuse: Bear the electric
current in the battery directly. When
it is burnt, no electric component can
Vehicle Operation Manual
work normally. If so, please check using the aluminum foil or
the circuit of the charging system. aluminum wire and other
Note: substitutions are not allowed. If the
If the major fuse is burnt, the users fuse is burnt in a very short time, it
shows there are big problems with
should replace it instead of using the
wire etc as substitute which may the electric, please go to Dongfeng
cause the damage of the electric SOKON Auto Maintainance Station
system, even the fire. for help.
② Fuse of Branch Circuit
Note:
The fuse box lies in the left of the
In order to guarantee that there are
pedal bracket. When take down the
spare fuse for replacement, three
fuse, first remove the cover of the
10amp and 15amp fuses will be
fuse box, and draw out the fuse. In
prepared in the fuse box.
order to differentiate the capacity
22. Air Window Cleaning
(amp) position of the fuse, please
Liquid
refer to the indication diagram on
Check the container for cleaning
the cover of the fuse box.
liquid, if there are not enough
Note:
cleaning liquid, please complement
Users should use the right capacity
it.
fuse while changing the burnt fuse,
45

Note:
If the electric machine works
without cleaning liquid, it will cause
damage. Do not use the engine
antifreeze instead of cleaning liquid,
or else, it will damage the oil paint.
23. Replacement of the Bulbs
Different Lamps
Note:
Please replace the bulb when it cools
down.Halogen lamp is very hot
while in the course of lighting or at
Vehicle Operation Manual
the moment of being closed and will
damage the skin and cause fire,
please wait till it cools down and
take it off by wrapping it with soft
cloth.If the bulb is frequently burnt,
it shows that there are some
problems with the circuit. Please go
the Dongfeng SOKON Auto
Maintainance Station for help.
23. Replacement of the Bulb
① Open the front storehouse cover.
② Remove two screws and draw
out the headlight forwad.
③ Pull out the flashboard.
④ Remove the pressurized rubber.
⑤ Push forward the spring making
it release from the hook, then change
the headlight bulb.
⑥ Contrarotate the tailstock of the
turning lights and then removes the
bulbs for replacement.
23. Replacement of the Bulbs
See the picture, use an opener as that
in the picture and wrap it with soft
cloth, then pry down the glass cover
to replace the bulb.
23. Replacement of the Bulbs
46

Turning Lights, Side Turning Lights,
Rear Assembled Lights, Liscence
Lights
There are two forms of bulbs (ellipse
or roundness), and the ellipse bulb
can be simply pulled out or inserted
in.
While remove the round bulb from
the socket, please first press the bulb
in and then contrarotate a little and
then pull out.
23. Replacement of the Bulb
① Remove bumper
② Pull out the flashboard.
Vehicle Operation Manual
③ Remove the pressurized
rubber.
④ Push forward the spring
making it release from the hook,
then change the headlight bulb.
23. Replacement of the Bulb
① Remove two screws and
draw out the headlight forwad.
② Pull out the flashboard.
③ Remove the pressurized
rubber.
④ Push forward the spring
making it release from the hook,
then change the headlight bulb.
⑤ Contrarotate the tailstock of
the turning lights and then removes
the bulbs for replacement.
24. ECU
ECU is the key component of
electric control system, inside which
there are designed process and
demarcated data for controlling
running. Do not pull out the cable at
will at any cases so as to avoid the
loss of the data. If there are any
troubles, please go to Dongfeng
Sokon. Auto Maintainance Station
for help.
47

Note:
Please prevent the ECU from water
while in rainy day or while washing.
24. Electric Control Unit
Note:
Don't electrification is it dial ECU
plug to insert, is it is it " blow fire "
way carry on circuit is it check to set
up an electric circuit " to adopt to
forbid, is it adopt power of
charger ,etc. carry on starting to
forbid, car body is it should remove
ECU when welding to need.
25. Ignition Timing
The integrated electric ignition
system for is a totally electric
ignition free of adjustment. The
system has cancelled such parts as
bypass and contact point etc., and
the ignition timing is controlled by
the ECU.
Vehicle Operation Manual
Note:
26. Use of Jack
Be careful if the vehicle rises
vertically in the course of jackup.
If the jack begins to incline, please
correct it to the right position.
Jackup on the slope is not allowed.
And any person shall not be under
Jack and rock rod of the jack should the vehicle while jacking up to
be kept in the cover board of the prevent the damage to people.
front storehouse. After using, please
return to the storehouse and make 27. Extinguisher
sure they have been fixed up firmly. Please refer to the Instruction
While using the jack, the vehicle Manual for the operation guide of
shall be put in the horizontal and Extinguisher.
hard ground. If you stop the vehicle
on the road, please turn on the 28. Triangle Warning Plate
emergency light.
Lock up the parking brake, and put
gearshift rod in the reverse gear, and
fix the the tire on the cross of the
rising angle by chock.
Put the jack under the jacking
position and upright jack up the
vehicle steadily and slowly to the Please refer to the Instruction
proper position; do not jack up the Manual for the operation guide of
vehicle too high.
48
 Vehicle Operation Manual
Triangle Warning Plate.

49
 Checkout & Maintenance Service

6. Checkout & Maintenance Service

50
 Checkout & Maintenance Service
1. Daily Inspection ○13 Fuel Level pertinence measure in time. With go

Daily inspecton is a necessary work

○14 Door Lock kilometer count or moon count as
standard confirm maintain time form.
for driver. The condition of the
○15 Rear Mirror
Every inspection, adjust, lubricate
vehicle changes every day, so please ○16 Licence Plate should stipulated time go on
check it before driving, which can 2. Regular Inspection and according to form strictly with other
help find the problems and solve maintenance work.
them before driving to enable to be Maintainance Note:
safe. The maintence items with mark ‘*’
○ 1 Fan belt 3. Regular Maintainance should be carried out by the special
○ 2 Engine oil maintainer. While regarding to items
without ‘*’ can be do maintenance
Period & Project
○
3 Cleaner
according to the instructions, and if
○
4 Battery Electrolyte Level The following form will introduce you think you cannot do that, please
○
5 Engine Coolant some checking items; we can find go to the special maintainer’s of
⑥ Stroke of Brake Pedal problems while checking and take Dongfeng Sokon.
measures accordingly. The running
○7 Tire
kilometers and months will be the
If it is necessary to replace parts,
○8 Free way of Clutch Pedal
standard maintenance time. The
you are suggested to use the
supporting parts of Dongfeng Sokon.
○9 Turning Operation check , adjustment, lubricant and to guarantee the quality.
○
10 Indicator Light & other maintenance service should be
Indicator Meter strictly subject to the stipulated time 4. Regular Check and
○ 11 Lighting System in the form.Make form recommend
several project of checking Maintainance
○ 12 Instruction of Electric Jet
emphatically, through is it pinpoint
Failure
the problems to check , take the Signs for Regular Maintenance

51
 Checkout & Maintenance Service
‘G’ means change
‘R’ means needing to be lubriacant.
‘X’ means screwing to the regulated
torque.
‘J’ means checking.
‘T’ means adjustment.

52
 Checkout & Maintenance Service
5. Regular Maintainance Items & Period
Term: based on the speed of the Km×100
10 20 30 40 50 60 70 80
speed table reading or the number of 0
months (whichever comes first)
Months 6 12 18 24 30 36 42 48
Items

Engine
1. Fan（Water Pump, Compressor）
— G — G — G — G
Drive Belt（Strain, Abrasion, etc.）
*2. Camshaft Synchronization Tooth
— J.T.G — J.T.G — J.T.G — J.T.G
Belt(Strain, abrasion, damage)
*3. Valve Gap — J.T. — J.T. — J.T. — J.T.
*4. Engine Bolt（all cylinder cover,
— X — X — X — X
fixing piece）
5. Machine Oil Cleaner G G G G G G G G
6. Machine Oil Replace for every 5000km
7. Engine Coolant Infuse at any time
*8. Soft Tube and Tie-in of Colling
System( Soft Tube and Tie-in of
— J.T.G — J.T.G — J.T.G — J.T.G
Colling System(leaking ,damaging
etc.)
*9. Exhaust System — J.T.G — J.T.G — J.T.G — J.T.G

53
 Checkout & Maintenance Service
Ignition System
*10. Ignition Coil(damamged,
— J.T.G — J.T.G — J.T.G — J.T.G
deformed)
*11. Spark Plug G G G G G G G G
*12. Ignition Timing J.T. J.T. J.T. J.T. J.T. J.T. J.T. J.T.

Fuel System
Cement or asphaltum
13. Air Clean while driving for every10000km, replace for every 40000km
road
Cleaner
Gravel Road Clean while driving 25000km, replace for every 40000km
*14. Fuel Box, fuel pipe and tie-in J.T.G — — J.T.G — — — J.T.G
*15. Fuel Cleaner G G G G G G G G
Exhaust Control of Crankcase
*16. Exhaust Soft 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

Electric Equipment
*19. Electric Wiring, Connect &
— J.T.G — J.T.G — J.T.G — J.T.G
Lamps

Chassis & Body

*20. Clutch J.T. J.T. J.T. J.T. J.T. J.T. J.T. J.T.

54
 Checkout & Maintenance Service
*21. Brake Fluid（liquid mass,
J.T.G J.T.G J.T.G G J.T.G J.T.G J.T.G G
leakage）
*22. Brake Pedal（stroke） J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
*23. Manual brake rod & cable J.T. J.T. J.T. J.T. J.T. J.T. J.T. J.T.
*24. Front: Brake plate&brake caliper
J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
friction
*25. Rear: Brake Drum & Brake
J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
Shoes
*26. Brake Soft Pipe &
J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
Pipeline(Leakage, damage)
27. Tire(Abnormal Abrasion,
J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
Abnormal Air Pressure)
28. Wheel & Boss Nut J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
*29. Bolt & Nut（Elasticity） — X — X — X — X
*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
Elascticity）

Cooling System
*31. Refrigerant Complement At Any Time
*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 — — — — — —
R R
*34. Condensor Check and Wash At Any Time

55
 Checkout & Maintenance Service
*35. Evaporator — — — J.T. — — — J.T.
*36. Desiccator — — — G — — — G
*37. Refrigerate Pipeline — X — X — X — X

56
 Malfunction Analyse & Elimination

7. Malfunction Analyse & Elimination

57
 Malfunction Analyse & Elimination
1. Malfunction of Engine System
Problems Reasons Solutions
Starting Problems 1. Failure of Ignition System Replace
1.1 Damage of the Protecting Device Repair or Replace
1.2 Failure of the Spark Plug Repair or Replace
1.3 Joint of High Voltage Damping Wire Loose or Replace
being Damaged
1.4 Damage of Ignition Coil
2. Failure of Fuel System Infuse Gasoline
2.1 Lack of Gasoline Clean or Replace
2.2 Gasoline Cleaner Blocked Clean
2.3 Fuel Pipeline Defiled or Blocked Repair or Replace
2.4 Electric gasoline pump doesn’t work Rectify
2.5 Impurity Fuel (eg. Including water)
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 Replace
4.1 Rupture of Timing Belt Reliable Connect
4.2 Vacuum Soft Pipe inconnect

58
 Malfunction Analyse & Elimination
Decrease/lack of the 1. Malfunction of Ignition System Adjust or Replace
Engine Power 1.1 Inprope Spark Plug Gap or Burnt Repair or Replace
1.2 Poor Connect/ Damage of High Voltage Clean
Damping Wire Clean or Replace
2. Malfunction of Fuel System Repair or Replace
2.1 Block of Fuel Soft Pipe or Oil Pipe Clean or Huff
2.2 Block of Gasoline Cleaner or Air Cleaner Replace
2.3 Oil Supply of Gasoline not enough Replace
2.4 Trouble with Piston Valve
2.5 Broken gasket of intake branch pipe
2.6 Incorrect fuel trademark
3. Insufficient Crock Pressure As Above Mentioned
4. Others Repair or Replace
4.1 Brake Problems Adjust or Replace
4.2 Clutch Skidding Reliable Connect
4.3 Connect Flex or Vacuum Soft Pipe Break Off
Unstable Idle Speed of 1. Trouble with Fuel System Clean or Replace
Engine 1.1 Block of the Air Cleaner Replace
1.2 Leakage of Intake Branch Pipe
2. Mafunction of Ignition System Adjust or Replace
2.1 Improper or Burnt Spark Plug Gap Replace or Connect
2.2 Breakoff or creepage of High Voltage Damping
Wire
3. Lack of Crock Pressure As mentioned above

59
 Malfunction Analyse & Elimination
4. Others Reliable Connect
4.1 Connect Flex or Breakoff of Vacuum Soft Pipe Replace
4.2 Failure of PCV of Crankcase
Abnormal Noise in the 1. Valve Noise Adjust
inner side of the Engine 1.1 Improper Valve Gap Replace
1.2 Abrasion of Valve Rod & Valve Guide Pipe Replace
1.3 Failure or Damage of Valve Spring Replace
1.4 Distort or Curve of Valve
2. Abrasion of Piston, piston ring and Valve Repair or Replace
3. Rod Noise Replace
3.1 Rod Bearing Abrasion Repair or Replace
3.2 Winch Pin Abrasion
4. Crank Shaft Noise Replace
4.1 Bearing Abrasion Repair or Replace
4.2 Crank Shaft Neck Abrasion Screw Down
4.3 Bearing cover bolt flex Replace the thrust-piece
4.4 Gas of crank shaft thrust-piece too big

60
 Malfunction Analyse & Elimination
Engine Superheating 1. Insufficiency of Coolant Complement Coolant
2. Air Resistance in Cooling Sytem Gas freezing & adding coolant
3. Loose of Water Pump Belt Adjust
4. Malfuction of Thermostat Replace
5. Poor Performance of Water Pump Replace
6. Too Much Begrime in Cylinder Body AND Repair or Replace
Cylinder Cover Clean or Repair
7. Block or Leakage of Radiator Choosing the right kind
8. Incorrect Engine Oil Kind Replace or Clean
9. Block of Engine Oil Cleaner or trap valve Add
10. Insufficient of Engine oil Repair or Replace
11. Poor Performance of Oil Pump Repair or Replace
12. Brake Seizure Repair or Replace
13. Clutch Skidding Replace
14. Damage of Cylinder Cover Gasket
Consumption of Engine 1. Leakage of Engine Oil Screw Down
Oil 1.1 Flexible Discharging Oil Bolt Screw Down
1.2 Bolt of the Oil Case Flexible Replace the Sealling Glue
1.3 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
1.8 Oil Leaking of Cylinder Cover Replace
1.9 Oil Line of the Clyinder Blocked and leaking

61
 Malfunction Analyse & Elimination
2. Engine Oil Entering the Firebox Clean of Sand
2.1 Piston Ring Locked Repair or Replace
2.2 Abrasion of Piton Ring & Groove Repair or Replace
2.3 Abrasion of Piton Ring & Cylinder Adjust
2.4 Piston Ring not Stagger as regulated Replace
2.5 Abrasion of Valve Oil Seal Replace
2.6 Abrasion of Valve Rod Replace
2.7 Damage of Cylinder Washer Screw Down or Replace
2.8 Breakoff of Rocker arm Screw
High Consumption of 1. Malfunction Of Fuel System Repair or Replace
Gasoline 1.1 Fuel Tank, Carburetor or Leakage pipeline Repair or Replace
1.2 Block of Air Cleaner Connect or Replace
2. Malfunction of Ignition System Adjust or Replace
2.1 High Voltage Damping Wire Flexible or
Creepage
2.2 Malfunction of Spark Plug(Improper Gap,
Burnt, accumulated carbon)
3. Insufficient of Cylinder Pressure As Above Mentioned
4. Others Repair or Replace
4.1 Poor Valve Seat Repair or Replace
4.2 Brake Seizure Replace
4.3 Malfunction of Thermostat Adjust
4.4 Abnormal Tyre Pressure

62
 Malfunction Analyse & Elimination
2. Malfunction of Clutch
Problems Reasons Solutions
Clutch Skid Improper free stroke of Clutch Pedal Adjust the Free Stroke
Clutch Flake Abrased or with Oily Soil Replace Clutch Flake
Deformation of Compressive Plate or Flywheel Replace Clutch Flake, Clutch
Surface Compressive Board or Flywheel
Diaphragm Spring Weak Replace Clutch Cover
Clutch Cable Rust Replace Cable
Hard Seperation of Improper Free Stroke of Clutch Adjust Free Stroke
Clutch Diaphragm Spring Weak or Abrasion of Reed Replace Clutch
Input Spline Rust Lubricating
Damage or Abrasion of Transmission Input Shaft Replace Input Oil
Spline Replace Clutch Flake
Serious Sway of Clutch Flake Replace Clutch Flake
Clutch Flake Abrased or with Oily Soil

63
 Malfunction Analyse & Elimination
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
Torsional Spring in the Clutch Flake Weaken Replace Clutch Flake
Loose Rivet of Clutch Flake Replace Clutch Flake
Deformation of Compressive Plate or Flywheel Replace Clutch Cover or Flywheel
Surface Screw Down Again or Replace
Fixing Wahser of Engien Becoming Weak, and fixing Washer
Fixinjg Bolt or Nut Becoming Flexible
Clutch Sounding Abrasion or Damage of Separate Bearing Replace Separate Bearing
Abrasion of Front Input Shaft Bearing Replace Input Shaft Bearing
Loose of Clutch Flake Hub Replace Clutch Flake
Crakes in Clutch Flake Replace Clutch Flake
Compressive Plate or the Diaphragm Spring Loose Replace Clutch Cover
Clutch Jammed Clutch Flake Soked with Oil Replace Clutch Flake
Serious Abrasion of Clutch Flake Replace Clutch Flake
Rivet Coming out of Flake Replace Clutch Flake
Torsional Spring Weaken Replace Clutch Flake

3. Malfunction of Transmission
Problems Reasons Solutions

64
 Malfunction Analyse & Elimination
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. Fix
Hatch Spring Ring breaking off
Not Off Gear Elasticity of the Synchronizer Spring Weakened or Replace
the Spring Broken Replace
Deformation of Gearshift Axle or Gearshift Fork
Gearshift Troubled Incorrect Clutch Pedal Stroke Adjust
Deformation or Break of the Cluch Friction Disc Replace
Damage of Clutch Compressive Plate Replace Clutch Cover
Abrasion of Synchronizer Alligatoring Ring Replace
Deformation of Gearshift Axle Replace Gear
Replace
Noise Insufficiency Lubricant or the Improper Type Complement or Replace

Damage or Abrasion of Bearing Replace

Damage or Abrasion of Gear Replace
Damage or Abrasion of Synchronizer Alligatoring Replace
Ring Replace
Abrasionor Damage of Gear Sleeve etc.

4. Malfunction of Differential Gear

65
 Malfunction Analyse & Elimination
Problems Reasons Solutions
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
Improper Connect between Taper Driving Gear & Replace or Screw Down Again
its Driven Gear Replace
Loose of Setting Bolt of Taper Driven Gear
Damage of Differential Gear or Driving Gear
Bearing Noise Gear Oil going bad or including water Replace Oil & Re-infuse
Insufficient Gear Oil or Incorrect Kind Replace Oil & Re-infuse
Damage of Taper Driving Gear Bearing(noise Replace
sending off while Gliding) Replac
(Noise while rotating,) Damage of axle bearing of
differential gear or the back axle bearing
Oil Leakage Chock of Vent Blocked Clean
Abrasion or Damage of Oil Seal Replace
Too Much Oil Adjust Oil Level

5. Malfunction of Steering System, Suspension System, Wheel and Tyre System

Problems Reasons Solutions

66
 Malfunction Analyse & Elimination
Wheel Tyre not matching or Asymmetry Replace
Running(deviating ) Improper 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 & Adjust the Front Wheel
One Running Wheel Seizure Alignment
Or Rear Suspension Flexible, Bent or Damaged. Repair Brake
Screw Down or Replace the
Suspension
Abnormal Abrasion or Sagging or Damage of Spring Replace Spring
over-Abrasion of Tire Imbalance of Tire Adjust to make it Balance or
Maladjustment of Front Wheel Alignment Replace Tyre
Trouble with Strut (Shock Absorber) Check & Adjust Front Wheel
Bad Road Condition Alignment
Overloading Replace Strut
Tyre not Transposition Replace Tyre
Abrasion or Sagging of Wheel Bearing Replace Tyre
Sway of Wheel or Tyre Replace or Reposition
Insufficient of Air Pressure of Tyre Replace Wheel Bearing
Replace Wheel or Tyre
Adjust Air Pressure of Tyre
Wheel Shocked Tyre Damaged Replace Tyre
Improper Strut (Shock Absorber) Replace Strut

67
 Malfunction Analyse & Elimination
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
Abrasion of left/right front Suspension Wall Round Replace the end of turning sidelong
Head coulping bar
Immoderate wheel radial jump Front suspension arm
Bulge or damage on the tire Repair or replace wheel and/or tire
Tyre/wheel radial jumping overloadingly Replace the tire
Maladjustment of Front Wheel Alignment Replace tire or wheel
Turning Driving Rodbecoming flexible or being Check & Adjust the front wheel
abrased alinment
Fixing bolt of turning gear box becoming flexible Screw down or replace the driving
rod
Screw down the turning gear bolt
Turning Problems Improper Charge Pressure of Tyre Charge the Tire to the Proper
Sluggish of Steering Global Scolex or L/R Global Pressure.
Scolex of Suspension Arm Replace the Steering Global Scolex
Maladjustment of Front Wheel Alignment or the front Suspension Arm
Improper Adjustment of Rack and Pinion Check & Adjust Front Wheel
Sluggish of Steering Wheel Alignment
Check & Adjust the Torque of the
Rack & Pinion
Repair or Change
Turning Windage too Big Abrasion of Wheel Bearing Replace Wheel Bearing

68
 Malfunction Analyse & Elimination
Bolt of Turning Gear Case Loosened Screw Down
Incorrect Adjustment of Rack & Pinion Check & Adjust Torque of Rack &
Abrasion of Turning Axle Gimbal Pinion
Abrasion of the turning sidelong coupling bar end Replace u-joing
or its inner side global joint. Replace the turning sidelong
Abrasion of Global Joint of Left/Right front coupling bar end or turning sidelong
suspension arm. coupling bar
Replace Front Suspension Arm
Poor return(Turning) Jamming of turning sidelong coupling bar end. Replace the turning sidelong
Jamming of Global Joint coupling bar end
Jamming of Steering Column Replace Front Suspension Arm
Poor Lubricant of Rack & Pinion Repair or Replace
Maladjustment of Front Wheel Alignment Check, Repair or Lubricate the Rack
Improper Adjustment of Rack & Pinion & Pinion
Improper Charge Pressure of Tyre Check & Adjust Front Wheel
Alignment
Check & Adjust Torque of Rack &
Pinion
Adjust Air Pressure of Tyre
Noise while Turning Bolt of Turning Gear Case Loosened Screw Down
Wheel Bearing Damaged or with other problems Replace
Abrasion of the turning sidelong coupling bar end Replace
Improper Adjustment of Rack & Pinion Check & Adjust Torque of Rack &
Pinion

69
 Malfunction Analyse & Elimination
Abnormal Noise with Abrasion of unworkable or loose of the turning Repair or Replace
Front Wheel sidelong coupling bar end, global joint(left/right Replace
front suspension arm), inner side global joint of the Screw Down Bolt, Replace Bush
coupling bar or tramsmission shaft joint. Screw Down Wheel Nut
Damage of Strut or fixing piece Screw Down the Bolt or Nut
Abrasion of suspension arm bush Replace Wheel Bearing
Stabilizer bar becoming flexible Replace Spring
Nut of wheel becoming flexible Infuse Lubricant or Replace Strut
Bolt or nut of the suspension shelf becoming Bearing
flexible Replace
Damage of the wheel bearing or other problems
Damage of the spring of the suspension shelf
Poor Lubrication or Abrasion of Strut Bearing
Abrasion of the joint of stabilizer bar
Sway while Turning or Tyres not matching Replace Tyre or Charge the Tyre to
Turning with Poor Damage or Sagging of Spring Proper Pressure
Stability Improper Adjustment of Rack & Pinion Replace suspension arm or the end
Improper Front Wheel Alignment of turning sidelong coupling bar.
stabilize connecting rod loose Replace Strut or Repair
Replace Spring
Check & Adjust Torque of Rack &
Pinion
Check & Adjust Front Wheel
Alignment
Replace stabilize connecting rod

70
 Malfunction Analyse & Elimination
Instable Turning while Abrasion of Wheel Bearing Replace Wheel Bearing
Brake Damage or Sagging of Spring Replace Spring
Insufficient Charge of Tyre Charge the Tyre to Proper Pressure
Improper Front Wheel Alignment Check & Adjust Front Wheel
Alignment
Height of the actural Rupture or Sagging of Spring Replace Spring
vehicle disaccord Overloading Check Carrying Load
Improper Use of Spring Replace Spring
Feel loose while driving Shock Absorber or Strut with Troubles Replace Shock Absorber or Strut
Suspension arm being Overloading Check the Carrying Loading
pressed to the bottom Shock Absorber or Strut with Troubles Replace Shock Absorber or Strut
The vehicle decline or Spring with Troubles or Sagging Replace Spring
shake while turning Loose of Stabilizer Bar Screw Down Stabilizer or Nut, or
Damage or Sagging of Spring Replace Bush or Joint
Overloading Replace Strut or Fixing Accessories
Replace Spring
Check Load
Tire becoming sunken Defective Front Strut Replace
Abrasion of Wheel Bearing Replace Wheel Bearing
Tire & wheel deflection too much Replace Tyre & Rim
Abrasion of Joint of Front Cantalever Replace Front Cantalever
Imbalance of Tyre Adjust the tyre

6. Malfunction of Heating System

Problems Reasons Solutions
71
 Malfunction Analyse & Elimination
Blower Fan not Wrok Blowoff of the Blower Fan Replace the fuse and check it.
while Putting the Electric Abnormal Work of Resistance of Blower Fan Replace Electric Machine
Source Through Abnormal Work of Resistance of Blower Fan Repair if necessary
Trouble With Wiring or Earthing
Incorrect Output Rupture or bent of the Control Cable Check the Cable
Temperature Damage of Air Damper Repair the Damper
Trachea Blocked Repair the Trachea
Leaking or Blocking of the Core of the Heating Replace the Core
Machine Replace the Soft Tube
Leaking or Blocking of the Heating Machine’s Soft
Tube

7. Malfunction of Cooling System

Problems Reason Solution
Air Conditioning not send Air Conditioner not Work Recycle, Pump out & Infuse
off (Abnormal Work of 1) Without Refrigerant Refrigerant and check the
Air Conditioner) 2) Blowout fuse ,heating
3) Trouble with Air Conditioner & Fan Switch Replace the Fuse of Air Conditioner
4) Low Idle Speed and Check if Short Circuit
5) Trouble with Air Conditioner Thermister Check the A/C & Fan Switch
6) Trouble with Air Conditioner Water Tempreture Check & Adjust the Idle Speed of
Sensor A/C
7) Trouble with High/Low Voltage Check the Thermister of A/C
8) Trouble with Top Air Conditioner Relay Check The Sensor
9) Trouble with accelerate-cut-off-switch Check the High/Low Voltage

72
 Malfunction Analyse & Elimination
10) Trouble with Line & Earthing Check the Top A/C Relay
11) Trouble with Air Conditioner Magnifier Check the accelerate-cut-off-switch
Repair as Requirement
Check the A/C Magnifier
Compressor not Work Check the Compressor Heat
1) Trouble with Compressor Heat Protector Protector
2) Trouble with Electromagnetism Clutch Check the Electromagnetism Clutch
3) Loose or Damage of Transmission Belt Screw Down or Replace
4) Trouble with Compressor Transmission Belt
Check the Compressor
Fan of Condensor not Work Replace Fuse & Check if it Short
1) Blowout Circuit
2) Trouble with A/C Condensor & Fan Relay Check Condensor Fan Replay
3) Trouble with Line & Earthing Repair as Requirement
4) Trouble with A/C Condensor & Fan Electric Check the Fan Electric Machine of
Manchine Condensor
Electric Machine of Fan not Work Check the Resistor of Fan Electric
1) Trouble with Resistor of Fan Electric Machine Machine
2) Trouble with A/C & Fan Switch Check A/C & Fan Switch
3) Trouble with Line & Earthing Repair as Requirement
4) Trouble with Fan Electric Machine Check the Electric Machine of Fan
Air Conditioning not Insufficient Complement of Refrigerant or too Check the Complement of
Send off or cooling not much Refrigerant
Enough(Normal Work of Condensor Blocked Check the Leakage and Condensor
A/C) Evaporator Blocked or Frozen Check Evaporator

73
 Malfunction Analyse & Elimination
Trouble with Air Conditioner Thermister
Trouble with A/C Controller
Trouble with Expansion Valve
Desiccator Blocked
Transmission Belt Skid
Trouble with Electromagnetism Clutch
Air Conditioning not Trouble with Compressor
Send off or not Air in the A/C
Enough(Normal Work of Air Leaking from TOP Evaporator or Windpipe
A/C) Trouble with heating system and aerator
Trouble with Fan Electric Machine
Excessive Compressor Oil in A/C
Cooling Intermittence Trouble with Line
Trouble with Expansion Valve
Too Much Humidity in A/C
Trouble with accelerate-cut-off-switch
Trouble with A/C Controller
Trouble with Electromagnetism Clutch
Trouble with Compressor Heat Protector
Infuse too much Refrigerant
Check the Thermister of A/C
Check the A/C Controller
Check the Expansion Valve
Check the Desiccator
Check or Replace Transmission Belt
Check the Electromagnetism Clutch
Check Compressor
Replace Desiccator, Pump Out &
Infuse Refrigerant , Repair if
Necessary
Check the Evaporator
Check the heating system
Check Fan Electric Machine
Pump Out Compressor Oil in A/C &
Replace Compressor
Repair if Necessary
Check the Expansion Valve
Replace Desiccator, Pump Out and
Complement Refrigerant
Check the accelerate-cut-off-switch
Check the A/C Controller
Check the Electromagnetism Clutch
Check the Heat Protector of
Compressor
Check the Infusing of Refrigerant
74
 Malfunction Analyse & Elimination
With Air Conditioning With Air Conditioning while Running at High Check the Condenor
while Running at High Speed Check the Complement of
Speed Complement of Refrigerant not Enough Refrigerant
Air in A/C Replace Desiccator, the Pump Out
Transmission Skid and Infuse Refrigerant
Trouble with Compressor Check & Replace Transmission Belt
Check Compressor
Without Air Conditioning Trouble with accelerate-cut-off-switch Check the accelerate-cut-off-switch
while Running at High Complement too much Refrigerant Check the Complement of
Speed Evaporate Frozen Refrigerant
Check the Evaporator
Check the Thermister of A/C
Insufficient Wind Power Evaporator Blocked or Frozen Check Evaporator
of Air Conditioning Cooling Sysem or the Windpipe Leaking Check the Thermister of A/C
Trouble with Fan Electric Machine Check Fan Electric Machine
Trouble with Line & Earthing Repair if Necessary
Noise in Compressor Trouble with Circumrotate Valve Replace
Trouble with Bearing Valve Replace
Trouble with Cylinder or Shaft Replace
Noise with Trouble with Bearing Replace
Electromagnetism Clutch Clutch Flake Damage Replace
Insufficient Air Gasket Damaged Replace
Conditioning Trouble with reed valve Replace

75
 Malfunction Analyse & Elimination
Not Circumrotate Electromagnetism Clutch Locked Replace
Circumrotate Part Locked for insufficient Machine Replace
Oil Replace
Machine Oil or Liquid Shaft Gasket Locked Replace
Leaking O-Ring Damaged Replace

8. Malfunction of Brake System

Problems Reasons Solutions
Insufficient brake force Oil leaking of Brake pipe Make sure the Leaking Part and
Oily Soil of Brake Disc or Brake Pad Repair
Brake Too Hot Clean or Replace
Poor Connection of Brake Shoe on the Brake Drum Repair or Replace
Oily Soil or Water with Friction Disc of Brake Shoe Repair to make it Connect Correctly
Abrasion of Liner of Brake Pad Replace
Damage of Wheel Cylinder Replace
Trouble with Brake Caliper Repair or Replace
Improper adjustment of the length transducer spring, Repair or Replace
if there is; Check or Adjustment
There is air in the system Exhaust
The transducer spring of LSPV is damaged. Replace
The ringer of LSPV is damaged.(if there is a ringer) Replace
Refer to ABS System
Brake Asymmetry (Work Friction Liner of Brake Pad and/or Friction Liner of Replace
of brake out of line) brake Shoe with water or Oily Soil. Check the ineffective antomatic
Maladjustment of gap between brake drum and brake adjusting machenism

76
 Malfunction Analyse & Elimination
shoe(Automatic adjust machenical failure) Replace
Asymmetry of Tire Air Pressure Charge averagely
Trouble wth Wheel Brake Pump Repair or Replace
Poor Adjustment of Front Wheel Adjust According to regulation
Tire not Same Use the same tire
Fluid not Smooth in Brake Oil Pipe or Soft Pipe Check if the tire internerate, oil pipe
Brake Caliper Trouble damaged, replace by the soft pipe &
Loose of suspension double level brake steel pipe.
Loose of Caliper Check the piston, caliper, lubricant
the slip bush.
Noise (while not braking) Abrasion of Front friction liner Replace Friction liner

Earlier Seizure of rear Improper adjustment of length of LSPV transducer Check or adjust
brake (only for vehicle spring Replace
with LSPV) Trouble with LSPV
Brake seizure(only for Troublw with ABS (ABS-ANTI-BRAKE Refer to ABS
vehicle with ABS) SYSTYEM)
Stroke For Pedals too long Trouble with part of Brake System Check the brake system, repair if
Insufficient brake liquid in liquid container of brake necessary
main pump. Infuse the regular brake liquid
Air in the brake system(pedal puniness) Check if the brake system leaking,
Rear Brake System not being adjusted(automatic with or without air.
mechanical failure) Check the warning light, exhaust air
Brake shoe bent if necessary
Abrasion of rear brake shoe Exhaust air
Repair the automatic adjusting
77
 Malfunction Analyse & Elimination
mechanism, and adjust rear brake
Replace brake shoe
Replace brake shoe

The brake cannot return The piston of main pump cannot return correctly. Repair the main pump
(while release the pedal, Flowoff of the brake oil pipe or soft pipe become Check if the tire internerate, oil pipe
the brake cannot return to smaller for being blocked. damaged, replace by the soft pipe &
its original position) Improper adjustment od stop brake in rear brake. double level brake steel pipe.
The return spring in brake cannot return or be Check and adjust according to the
damaged. techncal requirement.
Stop braking cable or pole react slowly Replace
Wheel brake pump or Caliper piston clipped Repair or replace
Serious abrasion of piston seal in caliper Repair if necessary
Trouble with ABS Replace the seal of piston
See ABS
Pedals jump(step on the Wheel and axle damaged or loose Replace wheel bearing
pedal brake, it jumps) Deformation of knuckle or rear wheel and axle Replace knuckle or rear axle
Radial jump of brake disc too big Replace or repair the brake disc if it
The parallelism fails to meet the requirement doesn meet the technical requirement.
Rear brake drum not round Check the radial jump, repair or
Replace if necessary.
Replace brake drum
Braking Noise Foreign matter attached to brake shoe Repair or replace
Abrasion or deformation of brake shoe Replace
Release of front wheel bearing Replace

78

Braking warning light is
on when starting the
engine
Braking warning light is
on when braking
Braking warning light is
not on while stop braking
ABS warning light will be
on while starting the
engine (if it has)
ABS warning light will be
on while braking(if it has)
9. Malfunction of Power Supply System
Problems
Malfunction Analyse & Elimination
Board deformed or bolt released. Replace or screw down the fixed bolt.
Stop brake is not released Release the stop brake, check and
Short of brake liquid turn off the braking warning light and
Brake pipe leaking infuse brake fluid.
Circuit problems with the brake warning light Check the leaking position, repair and
Trouble with ABS(if there is) infuse brake fluid.
brake pipe leaking Please see ABS
Short of brake liquid Check the leaking position, repair and
infuse brake fluid.
Infuse brake fluid
Trouble with the circuit of braking warning light Replace the bulb or repair the line
Trouble with ABS Please see ABS
Trouble with ABS Please see ABS
Reasons Solutions
79
 Malfunction Analyse & Elimination
While Switch on the Ignition & Turn Blowout Check the Fuse
off the Engine, Charging Light Not Bulb Burnt Replace the Light
On, Loose of the wire Connection Screw Down the Tie-in
Trouble with IC Adjuster or Magnetic Check the Generator
Field Coil Repair or Replace
Poor Connection of Brush & Slip Ring
Charging Light Still on While the Drving Belt Loose Adjust or Replace Driving Belt
Engine Running(Battery shall be Trouble with IC Adjuster or A/C Check the Charging System
charged frequently) Generator Repair the Line
Trouble with the Line

10. Malfunction of Lamps, Indicator Lights

Malfunction of Headlight
Problems
Headlights Not On
Only One Headlight Not On
Reasons Solutions
Bulb Damaged Check the Bulb
Trouble with the Headlight Switch Check the Headlight Switch
Blowout of the Headlight(L&R) Check Fuse, Replace if Necessary(If
Troublw with Wire or Earthing Replace, Check if it Short Circuit)
Check the Line
Bulb Damaged Check the Bulb
Blowout of Headlight(L/R) Check Fuse, Replace if Necessary
Trouble with Headlights Switch Check the Headlights Switch
Trouble with Wire or Earthing Check the Line

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Malfunction of Front Foglight
Problems
Front Foglight not On
Only One Headlight not On
Malfunction Analyse & Elimination
Reason Solution
Bulb Damaged Bulb Damaged
Blowout of the Foglight Check Fuse, Replace if Necessary(If
Trouble with the Switch of Front Replace, Check if it Short Circuit)
Foglight Check the Front Foglight Switch
Trouble with the Front Foglight Breaker Check the Relay
Trouble with Headlights Switch Check the Switch
Trouble with Wire or Earthing Repair the Line
Bulb Damaged Check the Bulb
Trouble with Wire or Earthing Repair the Line

Malfunction of daytime running lamps

Problems Reason Solution
Daytime running lamps not On Bulb Damaged Bulb Damaged
Blowout of the daytime running lamps Check Fuse, Replace if Necessary(If
Trouble with the control Replace, Check if it Short Circuit)
Work improper Standard work
Trouble with Wire or Earthing Repair the Line
Only One daytime running lamps Bulb Damaged Check the Bulb
not On Trouble with Wire or Earthing Repair the Line

Malfunction of Turning Signal & Emergency Light

81

Problems
High Frequency of Flicker or
Only One Side Flickers
No Flicker
Flicker Frequency too Low
Malfunction of Fender Taillight & Licence Light
Problems
Malfunction Analyse & Elimination
Reasons Solutions
Side Bulb with High Frequency Check the Bulb
Dmaged Check the Bul
Incorrect Bulb Euipped Check the Relay
Troublw with the Turning Signal or Repair the Line
Emergency Relay Repair the Line
Open Circuit or big Resistance Check the fuse and replace if Necessary
Exsisting between Switch of Turning Check the Bulb & Wire
Signal or Emergency light and lights Check the Relay
Troublw with Wire or Earthing
Fuse of Backup Light Horn & Backup
Signal Damaged
Open Circuit & Big Resistance
Exsisting between the Battery & Switch
Trouble with Turning Signal & Warning
Relay
Trouble with Combination Switch
and/or Warning Switch
Voltage of Electric Source Too Low Check the Charging System
Trouble with Turning Signal or Check the Relay
Emergency Relay
Reason Solution
82
 Malfunction Analyse & Elimination
All is not On Bulb Damaged Check the Bulb
Blowout of the Tailight, Parking Light Check Fuse, Replace if Necessary(If
Trouble with the Wire or Earthing Replace, Check if it Short Circuit)
Check the Line
Some Light Not On Bulb Damaged Check the Bulb
Trouble with Wire or Earthing Repair the Line

Malfunction of Backup Light

Problems Reasons Solutions
Backup Light Not On Bulb Damaged Check the Bulb
Blowout of the Backup Light Fuse Check Fuse, Replace if Necessary(If
Trouble with Backup Light Switch Replace, Check if it Short Circuit)
Trouble with Wire or Earthing Check the Switch
Repair the Line
BackUP Light not being Turned Trouble with Backlight Switch Check or Replace the Switch
off

Malfunction of Brake Light

83
 Malfunction Analyse & Elimination

Problems Reason Solution

Brake Light Not On Damage of Bulb
Blowout of the Rear Brake Light
Trouble witht the Brake Light Switch
Trouble with Wire or Earthing
Brake Light not being Turned Off Trouble with the Brake Light Switch
Check the Bulb
Check Fuse, Replace if Necessary(If
Replace, Check if it Short Circuit)
Check the Switch
Repair the Wire
Check, Adjust or Replace the Switch

Malfunction of Rear Foglight

Problems Reason Solution

Rear Foglight not On
Damage of the Bulb
Blowout of the Rear Foglight
Trouble with the Switch of the Rear
Foglight
Trouble with the Switch of Headlight
Trouble with the Wire or Earthing
Check the Bulb
Check Fuse, Replace if Necessary(If
Replace, Check if it Short Circuit)
Check the Switch of Rear Foglight
Check the Switch
Repair the Line

84
 Malfunction Analyse & Elimination
Fuel Meter & Fuel Measurement Module
Problems Reasons Solutions
Rear Foglight not On Blowout of the Fuse of Meter Board Check Fuse, Replace if Necessary(If
Trouble with Fuel Meter Measurement Replace, Check if it Short Circuit)
Module Check the Fuel Meter Measurement
Trouble with Fuel Meter Module
Trouble with the Wire or Earthing Check the Fuel Meter
Troublw with the Fuel Sensor Repair the Line
Check the Sensor

ECT & ECT Transducer

Problems Reasons
Thermometer of Engine Coolant Blowout of the Fuse of Meter Board
Not Work Trouble with the Engine Coolant
Thermometer
Trouble with the Engine Cooling
Tempreture Transducer
Trouble with the Wire or Earthing
Solutions
Check Fuse, Replace if Necessary(If
Replace, Check if it Short Circuit)
Check the Thermometer of Engine
Coolant
Check the Engine Coolant Tempreture
Transducer
Repair the Line

85
 Malfunction Analyse & Elimination
Warning Signal Light of Machine Oil Pressure
Problems Reasons Solutions
Warning Signal Light Bulb not Work Check the Bulb
not On while the Blowout of the Meter Board Check Fuse, Replace if Necessary(If
Engine not Start and Trouble with the Meter Line Replace, Check if it Short Circuit)
Ignition Switch is on Trouble with Machine Oil Pressure Switch Check the Line of Meter
Trouble with the Wire or Earthing Check the Machine Oil Pressure Switch
Repair the Line

Malfunction of Brake & Parking Brake Warning Signal Light

Problems Reasons Solutions
Brake Warning Signal Bulb not Work Check the Bulb
Light ot On while the Blowout of the Meter Board Check Fuse, Replace if Necessary(If
Brake Fluid below the Trouble with the Meter Line Replace, Check if it Short Circuit)
Fluid Level Trouble with the Brake Level Switch Check the Line of Meter
Trouble with the Wire or Earthing Check the Brake Level Switch
Repair the Line
Brake Warning Light Trouble with Ignition Switch Check Ignition Switch
not On (Ignition Trouble with Meter Line Check Meter Line
Switch on Start Trouble with Wire or Earthing Repair Line
Position)

86
 Malfunction Analyse & Elimination
Parking Brake Bulb not Work Check Bulb
Warning Light not on Blowout of Meter Board Check Fuse, Replace if Necessary(If
Trouble with Meter Line Replace, Check if it Short Circuit)
Trouble with Parking Brake Switch Check Meter Line
Trouble with Wire or Earthing Check the Parking Brake Switch
Repair Line

Warning Signal Light of Seat Belt

Problems Reasons Solutions
Warning Signal Light Bulb not Work Check the Bulb
not on Trouble with the Switch of Seat Belt Check the Switch of Seat Belt
Blowout of the Meter Board Check Fuse, Replace if Necessary(If
Trouble with the Line or Earthing Replace, Check if it Short Circuit)
Repair the Line

11. Accessories

Wiper & Washing Apparatus

Problems Reason Solution

87
 Malfunction Analyse & Elimination
Malfunction of Wiper Blowout of Wiper/Washing
or not Return to its Apparatus
Original Position Trouble with Wiper Electric
Machine
Trouble with Wiper Switch
Trouble with Line or Earthing
Malfunction of Washing Pipe or Nozzle
Washing Apparatus Blocked
Trouble with Washing
Apparatus Electric Machine
Truoble with Wiring &
Earthing
Check Fuse, Replace if Necessary(If Replace, Check if it
Short Circuit)
Check Wiper Switch
Check Wiper Switch
Repair Line
Clean or Repair the Blocked Pipe or Nozzle
Check Washing Apparatus Electric Machine
Check the Washing Apparatus Switch
Repair the Line

Malfunction of Cigarette Lighter

Problems Reason Solution

Cigarette Lighter not Blowout of Radio & Cigarette
Work Lighter
Trouble with Ignition Switch
Trouble with Cigarette Lighter
Trouble with the Line or Earthing
Check Fuse, Replace if Necessary(If Replace, Check if
it Short Circuit)
Check Ignition Switch
Check Cigarette Lighter
Repair Line

88
 Disposition of Emergency

8. Disposition of Emergency

89

1. Starting System Not
Work
① 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 totally, it generally shows
the storage battery electricity
exhaust or poor connecting of wiring
end. After Confirmation, charge the
storage battery or repair the connect
point.
② If the headlight keeps being on,
please check the fuse. If there are
still problems, there may be big
electrical problems; you should go to
Dongfeng Sokon. Auto for repair.
2. Instruction of Storage
Disposition of Emergency
Battery Connect Start
If the engine can not start because of
the storage battery, you can connect
one kind storage battery in parallel
or storage battery to change for
starting in order to help to supply
enough electric energy.
Note:
Storage battery can produce
explosive gas, and the causticity acid
in which and the big output electric
current may cause to be burnt. In
order to reduce personnel's injury,
you should follow following
information when work near storage
battery.
① Make you eyes protected, and do
not bend over the battery.
② Do not expose the battery to
direct fire or make it under the
spark.
③ Keep your eyes & skin away
from the storage battery acid. If any
part of the skin touches and holds
the acid liquid of storage battery,
wash the injured area completely
with water immediately, and ask
doctors and nurses for help.
Please follow the following
instruction while parallelizing the
battery to start:
① Put one good 12V storage battery
close to vehicle, and make the link
cable reach to the storage battery.
Make the two vehicles close to each
other but not touch each other while
using the storage battery on the other
vehicle.
② Connect the two ends of the first
cable with the anode of the
corresponding battery, and two ends
of the cable shall be connected to the
cathode of the corresponding battery
90

respectively. Pay attention that the
cable shall not be near to the belt
pulley, belt or fan.
③ Start the engine of the vehicle
with battery first, then start the
engine of the vehicle without
electricity.
④ Do counterclockwise according
to the above orders to backout the
connected cables.
Note:
If battery is installed again after
being removed, the original designed
condition will lose in ECUand you
may find the idle speed is too high
or too low when re-starting this is
not a trouble and it is unnecessary to
adjust, the ecu will adjust the idle
speed to the regulated value after
running 15 seconds at idle speed.
3. Overheating of Engine
Under the abominable condition of
Disposition of Emergency
driving a vehicle, the tempreture of
engine will temporarily go beyond.
If the temperature form of the engine
is pointedkout beyond the regulated
value, so:
① Turn off the A/C.
② Parking the vehicle in a safe
place, and make the engine running
for several minutes at idle speed till
the value of the water thermometer
go down to the safe range.
③ If the tempreture of the water
still does not go down, please check
the following items:
A. Check and verify whether the
water pump belt and belt pulley
damage and skid, and the working
condition of the fan when the engine
operates. If there is any thing
abnormal, please adjust it or fix a
breakdown.
B. Check the coolant level in the
water tank, if its location is lower
than " LOW " line, please look for
the leak point in water pump ,
radiator and water 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 then to the radiator carefully if
necessary.
Note:
If the deflation is to be seen or
heard, you should stop the vehicle
and turn off the engine to make it
cool. If not, you should open the
engine cover, check if the collant
boiling, if yes, wait till it stops.
4. Traction of the Vehicle
91

If need traction, please send for
professionalist or special maintainer
of Dongfeng Sokon. Auto.
Note:
The traction distance shall not
exceed 10m.
The traction speed shall not exceed
30km/h.
Unless emergency, do not tow the
vehicle by transporting pothook
generally.
Note:
In order to avoid damaging your
vehicle in the vehicle traction, please
adopt the correct equipment and
steps while traction.
Disposition of Emergency
Don't adopt the way in which the
rear wheel land while drawing
otherwise may cause the damage of
the gear box.
While the vehicle is dragged away,
the front wheels land and the rear
wheel.lifted. Put the ignition switch
on ‘ACC’ position to unlock the
steering wheel, the front 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
moveable platform. There are
transporting pothook at front and
rear end, which is only use for
transportation.
92
 Maintenance of the Vehicle

9. Maintenance of the Vehicle

93

1. Cleanness of the Vehicle
Inside
Vinyl Plastics
Make the spare liquor by mixing the
soap or neutral detergent and warm
water. Spread the liquor to the vinyl
plastics; make the dirt soften by
soaking several minutes. Polish the
internal and external surface of car
thus to remove the dirt and soap with
the clean warm cloth. If there is dirt
that still stays on the surface, repeat
above-mentioned procedures.
Cleanness of Fiber Material
Use the dust catcher to clean dust,
wipe the dirty place with the clean
cloth soaked with the gentle soap
liquid, and then wash with the
branch water.
Cleaness of Safety Belt
Wash the safety belt by water and
soap.
Maintenance of the Vehicle
Cleanness of the Vehicle Inside Vehicle’s Outer Part
Don't use bleaching agent or the
The dirt or any other things on the
dyestuffs to the safety belt; they will
paint will cause the following
make the intensity of the safety belt
problems as time goes on.
decrease.
① Cover paint Fades
Cleaning of the Floor
② The degradate lacquer film
Usually the filth can be cleaned up
causes the car body to get rusty.
by water & neutral soap from
ethylene plastic. Make the dirt soft ③ The scratch of the body caused
with brush, and then, washes the by dirt or other things may result in
floor cushion completely by water,
rust.
and dry by airing in the shady and
cool place. ④ The dirt will corrode the car body.
Note: So the more important thing is that
Do not use varnish thinner, petrol your car should be kept clean,
such volatility solvent or such
without dirt always, and keeps the
materials as bleaching agent, house
using strong syringe while scrubing cover paint in good condition to
inside and outside of the car. The protect the body from being
above-mentioned material may be
corroded.
toxicant or flammable; it will cause
the bodily injury or the vehicle to Cleanup & Wax of the Vehicle’s
damage by improperly use.
Outer Part
2. Cleanup & Wax of the The following should be followed
94

while washing the vehicle:
① Wash the bottom of car body in
order to remove the mud and grit
with the high-pressure water. Make
dirt with a little bigger water soft so
as to clean up completely.
② Remove the outside mud and dirt
of car body with the running water.
You can use the sponge stained with
water, the brush or the similar tool
don't be used or it may scratched and
replied the hard material which
covers the paint.
③ Wash the outer part of the
vehicle with sponge or soft cloth
which dipped into neutral detergent
or wash soap for petrol gently.
④ Once after the dirt is removed
completely, wash the detergent with
the running water.
Maintenance of the Vehicle
⑤ After washing, clean the car While using the cleaning agent, the
following precautions of
body gently with the wet cloth, and
manufacturer's regulation should be
dry it in the shady and cool place by paid attention to. Don't use strong
air. house using detergent or soap.
⑥ Check the spray paint surface to Cleanup & Wax of the
see if there are damages needing to Vehicle’s Outer Part
be repaired.
Note:
a. Clear up all damaged part and dry. Please do not wash the plastic parts
b. Mix the paint round, and repaired by steam and water whose
the damaged place gently with the temperature is above 82℃.
small brush. You are advised to make the vehicle
waxed & polished after washing to
c. Dry it up after painting.
make its cover paint protected and
Note: brighter.
After washing, please check whether ①Only wax and polishing
there are water entering the brake or
compound with high quality can be
not. If yes, please stepped on the
brake repeatedly and slowly to used.
dehumidify it during driving a ②While using wax and polishing
vehicle at a low speed.
compound, please pay attention to
following proceedings that the
Note: manufacturer stipulates.
95
 Maintenance of the Vehicle
③The chromed parts shall be waxed E. Don't spread the primer and
preventive oil paint layer on or
too.
around the exhaust system so as not
A. The damage of the auto’s surface
to cause the fire.
and the comeoff of the 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
vehicle. So, please keep the vehicle
clean.
C. When loading and unload some
goods like corrosivity material
articles, such as chemical article,
fertilizer, cleaning the article , alkali ,
sour , salt ,etc., which should be
packed in the special container to
transport , if there are leaking or
overflowing, please clean up
immediately.
D. Don't park your automobile in the
car moistly, poor ventilation place,
and don't wash the automobile in the
garage.
96