Preface

Thanks for your using JAC trucks! Before your using JAC trucks, please read this operating specification carefully and operate the trucks according to the specification to bring JAC trucks' excellent performance into full play and keep the trucks in a good running state in a long time! JAC trucks are developed and produced jointly by Anhui Province Automobile Research Institute and Anhui Jianghuai Automobile Co., LTD. As well as the road conditions are taken to fully condition, the domestic and overseas modern de sign and producing technique of body and chassis are absorbed and adopted to let JAC trucks bear good smoothness and possibility, safe and reliable brake, easy and light control, convenient usage and maintenance. As a result of continuous progress in the technique, JAC trucks are also innovated and improved. All the diagrams and data in the specification are based on the latest material when compiling. We would not inform you after making some modification on it. Please forgive us for it. For the reason of hastiness, there may be some defect in it, and we are honored to receive your suggestion and advice. The technology consultation telephone number: 0551-2296374 The service consultation telephone number: 0551-2296361 Anhui Jianghuai Automobile Co.

ANHUI JIANGHUAI AUTOMOBILE CO., LTD. May. 2008

Notice! Please read these following items carefully before using JAC trucks!
!"As regards JAC trucks, please pay attention to these following items: 1.It is forbidden to make refitting and adding equipment without our permission, especially on the electric appliance, brake, steering and so on that will affect the safety system of the products. JAC will not take upon herself the loss owing to your refitting and adding equipment without our permission! 2.when using JAC products, please make timely maintenance and service according to the service manual to bring the good performance of your loving truck into full play. 3.Please be sure to go to special repair shop of JAC for service if finding problems in using; please use genuine parts of JAC if needing to change parts. JAC will not take upon herself the loss owing to your not using genuine parts. 4.Any consumer that uses JAC complete vehicle or chassis is forbidden to change its product identification and name plate, or the consumer will be responsible for it. #"As regards the special purpose chassis of JAC, please pay attention to the following items: 1. It is forbidden to lengthen or widen the frame of JAC without JAC's permission, or you will take upon yourself the loss for it. 2.As regards the refitting on JAC special purpose chassis, all the refitting companies should not make the refitted mod els be contradict with the traffic regulations and the relevant rules of the nation, or JAC will not be responsible for it. ! Use of vehicle # Engine $ Chassis IV Electrical equipment % Vehicle service and maintenance & Trouble shooting ' Automotive model table of trucks ( Appendix Main files alone with the vehicle

Contents
1 21 29 55 61 65 85 89 94

. Use of vehicle
( ). Use of instruments and apparatuses in the cab

(!). Use of components in the cab ("). Start and running of vehicle

HFC1048
series trucks

( ). Use of instruments and apparatuses in the cab

1. Integrated switch and instru! ment cluster
Integrated lock switch (figure

1) Ignition switch Ignition switch is on the right side of integrated switch. It has four func tions: LOCK ACC ON START. When the key is on the 'LOCK' position, the ignition switch has been connect ed to the power source and the lockup of steering gear has been disengaged. Turn the key to 'ACC' position clockwise, the circuit of ac cessories like radio and tape player

tion of spring. The schematic dia gram of ignition switch is as follows.

Combination switch is under the control of the multifunction handle, which lies in the lower left and inferi or place of the steering wheel. It can control small light headlight head light dimmer and turning to the left or the right by two different movement modes. The symbol and function of the combination switch is as follows: ) The OFF symbol indicates that

tion of headlight. Keep on the turning of the left control handle clockwise by 30+ , the front headlight the rear small light and the instrument light can light. - The symbol is the indica tion of steering. Forward and back ward motion of the control handle can operate the left and right turning lamp and the turn light indicator in the instrument panel. Push the con trol handle forward in the horizontal direction, the right turning lamp lights and there has the indication of turn ing right in the instrument panel. On the other hand, pull the control han dle backward, the left turning lamp lights and there has the indication of turning left in the instrument panel. If

the control handle is in the middle position, then there has no indication of turning. . Dimmer of headlight: Lift the left control handle upwards gently and do the 'uplift -looseness' motion, it can control the dimmer function of the headlight. Uplift the handle once, high beam headlamp lights; loose the handle, it goes out. Repeating the above action can control the work status of the high beam head lamp to obtain the purpose of dim mer function when overtaking or passing in night.

below)

which is composed of steering shaft seat ignition start lock and combination switch lies underneath the steering wheel.

schematic diagram of ignition switch 2) Combination switch ( left control handle)

small light and headlight do not light. (But at this time the high beam can light if you put up the handle.) * The symbol is the indica tion of small light. Turn the control handle clockwise by 30+ ,and the front rear small lights and the instru ment light can light.

combination switch ignition switch

can be connected. Turn to the 'ON' position, and the instrument circuit is connected. If keep on turning until to the 'START' position, the engine can be started. You should unlash the handle of the key immediately after the engine started. And the key can

schematic diagram of integrated switch 2

return to the 'ON' position by the ac

left control handle

, The

symbol is the indica

HFC1048
series trucks

3)Combination switch handle)

(right control

the wiper. Turning the control handle clockwise in the horizontal direction can control the wiper. Turn the con trol handle clockwise by 12+ to the 'LO' position, then the wiper works with low speed. Keep the turning clockwise for another 12+ , the wiper can work with high speed. When the control handle is on the original posi tion, it can be disconnected or re turned automatically. , The symbol is indication of exhaust throttle assistant braking. Lift the right control handle upwards and do the 'uplift-looseness' motion. Up lift the handle, then the switch can be connected and the indicator lamp in the instrument panel lights. This shows that exhaust throttle assistant

braking works. If the accelerator pedal or the clutch pedal was stepped, the exhaust assistant brak ing should cancelled ment panel went out. 4) Other electric appliance switch ( seen in the left and below figure) Other electric appliance switches mainly include horn button, danger warning switch, fog lamp switch, courtesy lamp switch and ceiling light switch. ) The horn button is in the center of steering wheel, when the button is depressed it can hoot. * The symbol ( the right and below figure) is indication of danger warning switch. If the button is de automatically and the indicator lamp in the instru

pressed, the front

rear

left

right

5) instrument cluster

turning lamp flash at the same time and send out emergency signal for alarm indication. Press the button a gain, reset signal of the switch dis connected. , The symbol ( the right and below figure) is indication of the fog lamp. If pressed, the fog lamp lights. Press again, the switch resets. - Ceiling light signal indicates that the door of the vehicle is shut closely or not. When there have one door opened or did not shut closely, the ceiling lamp lights to remind driver. danger alarm and fog lamp switch other electric appliance switch instrument cluster(air brake)

right control handle ) The symbol is indication of the scrubber. When the washer con trol button on the top of the control handle pressed, the cleaning mixture (using antifreeze fluid in winter) in the window washer which lies in the right doorframe and underneath instru ment panel can be spouted to the windshield glass through the spout under the window. * The 4 symbol is indication of

instrument cluster(hydraulic brake) 5

HFC1048
series trucks

status of high beam or not. When the headlamp is on the high beam sta tus, the indicator lamp lights. , Fuel warning lamp( 1 turn left 2 high beam 3 turn right 4 fuel alarm 5 parking brake 6 charging 7 oil pressure alarm 8 braking fault 9 exhaust assistant brake 10 fog lamp 11 small light indicators Indicators (figure in the above page): ) Turn indicator lamp( ) when the turning control handle is on the left (right) turning position, left (right) turning indicator lamp flashes. If the warning switch is pressed, the left and right turning indicator lamps flash at the same time. * High beam indicator lamp( ) indicates that the headlamp is in the 6 alarm lamp lights. - Parking brake indicator lamp ! handle,the indicator lamp lights. lamp ! "#when pull up the parking brake ): fuel level alarm, when fuel is in shortage, fuel

oil pressure indicator lamp lights. When oil pressure is higher than the value, the oil pressure indicator lamp goes out. 0 Braking fault indicator lamp! indicator lamp lights. 1 Exhaust assistant brake indicator lamp ! braking operates,the indicator lamp "#when exhaust assistant when braking fluid is not enough, the "#

( ! ). Use of components in the cab

Cab
Brief description of the structure The driver cab is forward control cab with full metal enclosed construction. Window glass adopts panoramic camber windshield. In order to im prove the comfort, side panel with larger upside width and raised -roof cab have been adopted. Therefore the interior space of the cab can be more commodious and comfortable. Effective measures have taken in re duce noise heat insulation sound insulation and sealing. For instances, the section of roof forehead is en closed and strengthening rib is e quipped on the roof. There have

three asbestos heat insulating mat tress on the upside of the engine. Sealing of the door is double skin construction. At the aspect of safety, softening has done to the main parts, which can appear knocking easily with passengers.

so the customer can choose what you like ,for example , can choose the same way to sending wind.

The air condition system (choose to pack) 1.Brief introduction

The automobile air -conditioner and the automobile instrument panel is an integral body which have cold air and warm air machine. It has many useful functions , or example ,to making cold air ,warm air and to re moving frost . The air -conditioner system has four high and low steps ,

. Exhaust assistant brake indicator braking operates, the indicator lamp lights. When exhaust assistant brake is disconnected, the indicator lamp goes out. / Oil pressure indicator lamp ! indicates low - pressure warning of engine oil pressure. When oil pres sure is lower than 0.08-0.1Mpa , the "# "#when exhaust assistant

lights. When exhaust assistant brake is disconnected,the indicator lamp goes out. 2 Fog lamp indicator lamp ! indicator lamp lights. 3 Small light indicator lamp ! lights. When they work$he indicator lamp "# when braking fluid is not enough, the "#

2.Operation
2.1 To operating the engine 2.2 To press the switch for the air conditioner , then operating the air volume .The switch has four grades , from left to right ,so the air volume of air -conditioner will be more and more strong. 7

HFC1048
series trucks

2.3 To operating air -conditioner switches 5,then the compressor be gins to work at this time .The whole system will be colder. 2.4 Using the cold wind , please put the temperature adjusting handle 3 to the COOL position .Using the warm wind ,you should put in the HOT po sition .To changing the wind-position ,choose the handle 2 can make the cold (warm) breeze never lead with direction .If you want to using the warm wind ,you should be close switch of the air condition. 2.5 To turning the natural wind con version , then pressing the handle 1can make the natural wind from outside of the car.

3.Caution
3.1 You should be avoid the handle in the most cold position when using t he air -conditioner in order to pre vent evaporate the machine from frost. 3.2 Do not park the cars under the sun . 3.3 To using air -conditioners, you should be close windows and doors of the cab. 3.4 To cleaning the condenser , you should be wash with the compressed air or cold water ,do not wash it strictly with the hot water or steam. 3.5 The air-conditioner does not use in winter , however ,you should be revolve compressor once a week about five minutes .In order to main

tain the air -conditioner for normal worked. 3.6 If you want to use the air heater , the temperature degree of engine should reach to 70 4s above .At 04 s the automobile should not park in the cool environment, it should be use antifreeze fluid, in order to pre venting frost radiator and air heater. 3.7 If you do not know the preven tions about the air -conditioner , do not switch it , the in order to prevent results in trouble. The top of cab's ventilating device which has two ways for it .One is ex terior air with indoor ,another one is house airiness .

top of cab that you definite the top cab is closed. (2) Turn on the switch to "IN" then turn on the rotary knob to "OPEN" .

step opening, can improve the con venience for passengers getting on or off. The opening angle of the door can be 30o 57o and 90o. The for mer two angles are partially open and the last angle is full open. On all the three positions, the door can be in stable condition. outside door handle

ii. Indoor airiness

(1) Clockwise the rotary knob to clos ing the ventilator louver. (2) Turn to the switch to "out "which is the exhaust gear position.

i. Leading exterior air

(1) Clockwise the rotary-knob on the

Door
1) The cab door, which have three-

lock button 9

HFC1048
series trucks

2) Outside door handle Pull out the outside door handle, and then the door can be opened. Insert the starting switch key into the door lock and turn, the door can be locked. 3) The door can be locked outside without the key. First press down the lock button (figure in the above page) at the inner side of the door to the fixed position, then pull the out side door handle outwards and at the same time close the door. 4) Pull out the inside door handle, and the door can be opened. After closing the door, the door can be locked if the lock button is pressed down.

Cab seat
Cab seat can be classified as driver seat assistant driver seat and rear row seat. Driver back seat adopts up right seat. The angle of backrest and the fore-and-aft position of seat can be adjusted. The maximum ad justable angle of the backrest is 56o. The maximum adjustable distance of the seat is 160 mm. The seat adjust system is shown in the right figure. When vehicle is in the progress of maintenance, please clean the track assembly of the driver seat, recoat the lithium base grease, and tighten all joint nuts again. If found that the cab track slide seat has shaking or block because of distortion, it should be re paired or replaced with components.

Cab tilt lock mechanism

cab'srear bracket and so on.The cab to turnover is used by torsion power. Lock up system is composed of

1.chuck rod 2.overturn rod 3.safe locking hook

right/left lock unit ,turnover lock unit , short pull rod ,long pull rod ,rear bracket of cab and so on .All of this is to lock the cab too tightly.(as pic ture) Please read the tilting notes on the left door of the cab and on the upper flange of the wheel seriously before tilting the cab. The notes are shown in the upper figure notice Use and maintenance In order to tilting the cab reliably and running the vehicle safely, please pay attention to following contents. !1"Cab tilting method and relative attentive notices. support rod assembly ) When the vehicle is stopped on the horizontal road, you should make sure that there has enough space around the cab before tilting. Or else, the cab may be damaged while tilt ing. 11

schematic diagram of cab tilt locking device

Brief of the structure

The cab has turnover functions , also has turnover and lock up organiza tion . The turnover was composed of torsion bar, supporting -axle,

10

HFC1048
series trucks

* Pull up the parking brake; push the shifting lever into the neutral posi tion to avoid the self -sliding of the vehicle. , The cab door must be fastened up. You should take all goods on the instrument panel seat and floor away to avoid the damage of the door and the front windshield. First disengaged the locking function of the cab locking mecha nism when tilting the cab. . After the locking function disen gaged, hold the tilting rod with hand and pull up the safety lock hook at the same time to avoid the sudden uplift of the cab. / Raise the cab slowly until it is tilt ed to the maximum position, then 12

lock it reliably with lock arm on the rear bracket. It is shown in the right figure. 0 When lowering the cab down, first hold the tilting rod and disengage the locking function of lock arm on the rear bracket, then lower the cab down slowly. After the safety lock locked, fasten the locking mecha nism. !2"Inspection and maintenance assemblies which are ) Check periodically the rubber pad used to strengthen the front rear support, if find damaged, it should be replaced instantly. * Check periodically the locking sit uation of the locking mechanism, if invalidation of locking function found,

it should be repaired or replaced im mediately. , If felt arduous when tilting up the cab or heavy when dropping down the cab, the torsion rod is invalid. Re place the torsion rod. - When repairing the chassis, be fore removing of the cab, disengage the force of the torsion rod and op erate with following steps. a. Disengage the locking state, and tilt up the cab to the utmost position. b. Remove the shaft pin connected the rear support rod and the base board support of the cab. c. Push the cab forwards for some angle until the bolt on the torsion rod arm can be loosened. d. After the bolt removed, the torsion

rod cannot work. Now the cab can be removed ( The torsion rod can not be pulled out). Note: The above -mentioned work must be done by three persons at least because two or three persons cannot push the cab forward after the force of the torsion rod is disen gaged. . Before reverting the cab to the o riginal position, return the force of the torsion rod and operate with follow ing steps: a. Put the tooth part of the spline which is cut at the bottom on one end of the torsion rod in alignment with '1' position on the support axle tube and the spline tube, and insert the torsion rod into the support axle

tube out).

( for the rod which is pulled

state of suspending at the horizontal direction after dropped down. If nor mally, then lock the cab. / If find invalidation of the torsion rod, when replacing, operates ac cording to - ..

b. After mount the cab with support axle tube and the left right bracket together to the frame, put the '1' of hub splines on the torsion rod in alignment with the spline tooth which is cut at the bottom on the other end of the torsion rod, cover the hub splines on the torsion rod and insert the spline axle tube into the right bracket in the cab. c. Tilt the cab forwards until the bolt hole on the torsion rod arm aimed at the screwed hole on the right bracket in the cab, screw the bolt and tighten it. d. Put the cab down slowly, and check whether the cab is on the

("). Starting and running of the vehicle

1. Starting of the vehicle
1"Starting of the engine

When starting the engine, put the shift bar on the neutral position, turn on the ignition switch, check horns instruments on the instrument panel turning lamps mirror. ) Routine start 13 braking lamps the angle and position of the rear view

HFC1048
series trucks

Turn the key to the START position (shown in the right figure), the engine can start. After starting, loosen the accelerator pedal immediately and keep the engine working in low speed. Depressing the accelerator pedal violently is forbidden. * Start in winter When the weather is very cold, the start of diesel engine can take fol lowing measures: a. Cooling water use hot water, and unclose the drain switch when adding hot water. When the hot water flowed out and the engine body be came warmer, close the drain switch. starting switch b. Heat up the oil up to 8045904 , and then add it into the oil pan. After starting the engine, check the operating state of the engine and in struments at different rotating speed. Especially check the oil pressure. Check if there have leakage of wa ter oil and gas, check whether the 14

oil level is normal and the engine have abnormal noise. Check whether the color of exhaust is normal. , After starting the engine, do not depress the accelerator pedal vio lently, loosen the accelerator pedal to keep the engine operating on idle for some time. After the temperature of engine rises and the engine operates stably, uplift the clutch pedal slowly. - Generally after the temperature of engine become more than 604 and the operating (sound) of the engine components the reading of instru ments are normal, the vehicle can run. Do not run the vehicle in low temperature to avoid intense wear of the engine. 2"Starting and shifting of the vehicle

After engine operates normally, de press the clutch pedal, shift into low gear, loosen the parking brake, and press the horn once. Making sure that the vehicle can be operated safely, loosen the clutch pedal slowly and depress the accelerator pedal properly at the same time to start the vehicle. After starting the vehicle, the foot should get away from the clutch pedal. Do not keep the foot on the pedal to avoid the burning out of the clutch friction disc. Note: Do not let the vehicle running in first or second gear for long time to prevent from increasing the wear and the fuel consumption. Loosen the clutch pedal rapidly or depress the accelerator pedal insufficiently,

the engine can stop. When running the vehicle, shift the gear according to the change of road and landform. If find that the engine power is in abundance and the rotating speed rises, it illustrates that the primary gear is not appropri ate, the vehicle should be shifted to the next fast gear in time. After shift ing, if not finding shortage of power and chattering of transmission, the shifting operation can be considered right. If find shortage of power or the vehicle speed decreases, the vehicle should be shifted to a low gear. If the vehicle runs normally after shifting, the shifting into low gear is right. for safety, when swerve passing bridge and meeting, the vehicle can

run in moderate speed. On better running condition, the vehicle can op erate in fast gear, and at this time the vehicle speed is high, the fuel con sumption is low, the economy of fuel is good. When shifting, do not just see the shifting lever. You should watch for wards, hold the steering wheel steadily with your left hand, let the center of the palm of your right hand stuck to the top part of the shifting lever and push or pull it to the need ed position with the force of your right wrist.

15

HFC1048
series trucks

2.Running und

the vehicle
1) Running

backing and braking of

swerve

turnaro -

overloading of the engine. When running, do not increase or de crease the vehicle speed abruptly and not shake the steering wheel without reason, listen whether there is abnormal noise or not, check the reading and indicator lamp of all in struments for normalization. If find abnormal noise or abnormal events, stop the vehicle immediately and check it, take necessary adjustment and repair. When downgrading, do not stall the engine. When downgrading steep ramp, shift the shifting lever into low gear and take braking operation at intervals to avoid the over fast of the vehicle speed. When running across shallow river or

loblolly, prevent the water from enter ing into air intake lines of the engine rear axles and transmission case. Check rear axles and transmission case for entering water after pad dling. If find water, drain it and add gear oil with specified quantity. After paddling, the vehicle can not run in high speed. You should depress the braking pedal every now and then to resume the braking performance as soon as possible. When running on the ice or snow road, run with steady speed. Do not take emergency braking and not turn the steering wheel fiercely to avoid skidding danger. Keep long safety distance from the foregoing vehicle. When running in heavy rain, drive the

vehicle more carefully to avoid de creasing the braking performance of the brake because of moist. Do not take emergency braking operation to avoid the danger of skidding. 2) Swerve Swerve of the vehicle produces cen trifugal force which can be bigger when the vehicle speed becomes higher. The force can bring turning over in the transverse direction in serious condition. Therefore, at the 50 5100 meters position before turn ing the vehicle, you should ring the horn turn on the turning lamp and reduce the vehicle speed. When running on the freezing and muddy road or in the weather of heavy rain fog wind sand, reduce the vehicle

speed to less than 10 km/h, swerve the vehicle slowly alongside the right side of the road. When swerving, turn the steering wheel uniformly accord ing to the situation of road, the swerving track should be transited smoothly, the turning motion should not be too great or too small. Do not turn or return the steering wheel suddenly. Try your best to avoid tak ing braking operation while turning the steering wheel, especially emer gency braking. When steering, if found skidding of front wheels, put up the accelerator pedal and turn the steering wheel in the contrary direction; if found skid ding of rear wheels, turn the steering wheel properly along the skidding

direction, and after the skidding stops, correct the running direction. 3) Turning around When turning around for 180+ , select the square large -scale crossing or flat broad road which have little traf fic flux and turn around the vehicle at a time along the running direction. At the 505100 meters position in front of the turning spot, reduce the vehicle speed, shift into low gear and send out the turning around signal. When turning around with running forwards and backwards, first send out the turning around signal, reduce the vehicle speed and run towards the right side of road. When ap proaching the preset spot for turning around, observe the situation of road, 17

Keep enough distance to the forego ing vehicle when running on flat road. Select vehicle speed according to the vehicle model mission and concrete condition of road, generally select the speed of 50570 km/h. Let the vehicle running in the first or second gear when starting, upgrad ing under heavy load and running on bumpy road or on the road having obstacles. But the vehicle can not running in the first or second gear too long in normally running. When upgrading with heavy load, shift the shifting lever into low gear to avoid 16

HFC1048
series trucks

turn the steering wheel to the left ex treme position rapidly and let the ve hicle running to the left side of road slowly. When approaching the road side, return the steering wheel rapidly. After observing the situation behind the vehicle, start and turn around the vehicle, turn the steering wheel to the right extreme position at the same time. When approaching the roadside, return the steering wheel rapidly and stop the vehicle. If the turning around operation can not be done once time, repeat the above operations. 4) Backing The operation of shifting into reverse gear or shifting from reverse gear to onward gear can be done after the 18

vehicle is stopped completely. After shifting into the reverse gear, the back -up lamp lights. The vehicle speed must be less than 5 km/h when backing. If the driver can not discern the situation behind the ve hicle because the vehicle is loading or other reasons, the backing oper ation must be commanded by one person who is outside the vehicle. Do not back the vehicle blindly. 5) Parking of the vehicle and stop of the engine When preparing to park the vehicle, the vehicle speed reduces or the ve hicle slides out of gear and indicates with turning lamp. After the vehicle parked, pull up the parking brake lever. If the vehicle must be parked

on the road for some reason, park the vehicle near the roadside and not park the vehicle on the running lane. Under the exceptional condition like breaking down in the middle of road, two caution plates should be placed on the position of 200 meters in front of and behind of the vehicle. Avoid parking on the ramp. If the vehicle must be parked on the ramp, pull up the parking brake lever to the extreme position, shift into low gear and block the vehicle with triangular chocks or stones to prevent it from sliding. Note: Make sure that the parking brake can work reliably when parking on the ramp, at the same time turn on the emergency warning signal indicator lamp.

After parking, especially after the en gine operates with heavy load, do not stall the engine immediately, but keep the engine operating in low speed for several minutes. After the temperature of water decreases less than 704, then stop the engine. When parking midway in winter, take the heat preservation and antifreez ing measures for the engine. Prevent the oil tank from insolation in sum mer. After the vehicle runs a day, routine service and inspection should be done on the entire vehicle.

19

".Engine
( ). Inlet air exhaust systems

(!). Cooling system ("). Accelerating transmission system (#). Fuel supply system

21

HFC1048
series trucks

Notice#The details of the engine structure assembling adjustment using and maintenance can be consulted in the oper!
ating specification of relevant engines. The position of the engine card Cause#The card of engine is on the top cylinder head or on the side of engine .It writes the model number of engine , clearly and convenience.(as picture)

( ). Inlet air exhaust sys$ tems

ture

2) For every 1000km running, check the inlet and exhaust manifold for the following: a. Check nuts for looseness, when tightening the nut on the inlet and exhaust manifold, the torsion force should be equable, or else the air leakage can occur. b. Check the inlet and exhaust mani fold for crack and hole, check the gasket for damage and erosion, if found, replace it with a new one.

through the air inlet pipe, larger dust particle can be separated from the air by the function of cyclone vane, then can be thrown into the dust gathering plate, the separated air keep on moving and enter into the cylinder by the filtering function of the paper element. For every 1000km running, check and maintain the air filter. When run ning in the condition of excessive dust, the running mileage interval for inspection and maintenance should be shortened suitably. Cleaning of the air filter: 1) Remove the dish-shaped nut from the end cover. Take away the end cover, remove the inner nut and take off the filter element assembly. 23

1. Brief description of the struc!

Inlet system includes air inlet pipe assembly air filter assembly intake manifold. Exhaust system includes exhaust pipe tailpipe Use and maintance# 1) The service life of the engine has great relationship to the workmanship of the air filter. Absolutely forbid that the engine works without air filter or on the condition that the air filter is disabled. Taking the intake opening of air filter as the original intake open ing is forbidden. muffler and exhaust

sequence number ,declared power ,declared speed and the factory date .Pay attention to find it in order to using it

Air filter
The function of air filter is to filter out the dust and the sand in the air en tered into the engine. Air filter is cyclone dust gathering air cleaner with paper filter element. Af ter external air enters into the air filter

22

HFC1048
series trucks

2) Clean the cover cap and the inner part of the housing with dry and clean cloth.When cleaning, do not let the moisture enter into the air filter.

3) To cleaning dust unloading valve in order to usage well . 4) Tight and close the rubber of connected brake . 5) Clean the air filter element: clear away the dry dirt or dust with com pressed air gun (air pressure should be less than 690kpa),blow from the inner side of filter element towards outside. Do not clear away the dirt or the dust with beating or knocking.

The concrete structure and type of the cooling system components can be consulted in detail in the operat ing specification of relevant engines.

found it is not enough, add liquid to the specified height. 3) Drainage of cooling system. In cold region and in winter, without us ing antifreeze preservative liquid, if long time parking or receiving the vehicle everyday, the cooling system must be drained. And you should open the water filler cap of the radia tor to avoid the incomplete drainage of cooling water. 4) After engine operating for long time, furring can produce in the cooling water and it should be cleaned in time. Clean it with follow ing method: mix caustic soda 700 5800 gram and 150 gram

speed for 5 510 minutes, then after stopping for 10 512 hours, restart the engine and run for 10 515 minutes. Then drain the aqueous solution and clean the cooling system with cleaned water.

preservative liquid, replace it entirely at once. The color of antifreeze liquid is green or blue, if having deteriorat ed, the color should be dull red be cause of impurity infiltration.

2.Using and maintenance of cooling system

1) Recommend using long effective antifreeze preservative liquid for cool ing fluid. In the north, it can avoid the damage of engine because of the freezing of cooling fluid in winter; in the south, it can increase the boiling point of cooling fluid in summer to avoid the damage of engine over heating because of air resistance in high temperature. 2) Before dispatch the vehicle every time, check the liquid level in the ra diator and in the bulge radiator, if

3.Advertent proceedings in using vative liquid

To adjusting the degree of ten! sion of the fan belt

1.The disadvantage of engine is tighten or lax the fan belt .Before use it please read the operating specifi cation . 2.The way of adjustment :firstly to adjusting blots ,secondly to adjusting ,third to adjusting the tight of wedge -shaped belt .Using finger press way ,to pressing for 98/N .The standard of crankshaft pulley is 25% 7%8mm. 25 31mm .The standard of fan belt is

long effective antifreeze preser!

1) Choose suitable antifreeze liquid according to the minimum tempera ture of the region, if the minimum temperature of the region is -254 , antifreeze liquid whose solidifying point is -304 should be chosen. 2) When compensating antifreeze preservative liquid, choose the same model to avoid deposition. 3) If find deterioration of antifreeze

(!). Cooling system

1 3 4 5 6 7 8 9 cab 2 vent hose (1) of the air filter intermediate connecting pipe connection board vent hose of the air filter right longitudinal member of the frame air filter bracket intake pipeline of the air filter connecting hose 10 air filter schematic diagram of air filter

1.Brief description of the struc! ture

Cooling system is closed water cool ing pressure cycle type. It is com posed of radiator coolingfiuid ther mostat fan bulge radiator and wa ter inlet and outlet pipes of radiator.

kerosene, add the mixture liquid into the cooling water, run in medium

24

HFC1048
series trucks

( " ) Accelerating transmis$ sion system

ture

Accelerating transmission equipment is composed of accelerator pedal mechanism accelerator wire draw ing and acceleration governor arm of the engine. It is shown in the figure in the above page. When depress the pedal, driving medium of the mechanism pull the wire drawing, control the opening extent of the accelerator to increase or decrease the speed 1" Accelerator pedal mechanism: Accelerator mechanism take

bling and little operating noise. 2"Accelerating wire drawing: It operates by the soft wire drawing. And it has traits of reliable structure convenient layout little frictional re sistance and stable transmission. 3"Hand throttle wire drawing: Using with the foot throttle can quick en the preheating of the engine or in crease the idling speed.

without jamming. When releasing the pedal, it should be returned freely. 3) When depressing the pedal, if the free play is too big or the opening extent of the accelerator is not e nough, adjust the position of bolts.

pression ignition with the air rapidly. Its operating state has important in fluence to the power and economy performance of the engine. 1) Coarse cleaner#the car's fuel pip ing have a DX150T spin-on oil filter$ flow volume is 1.5L/min. It can transi and oil tion impurity and can separate water

2) Fuel tank:. The tank install the filter gauze inside the fuel filler port to pre vent impurity of large particle enter ing into the fuel tank, set oil drain plug on the bottommost position of the fuel tank to drain the deposit and water on the bottom of tank when cleaning the fuel tank.

1.Brief description of the struc!

!#" Fuel supply system

ture

1.Brief description of the struc!

Fuel supply system is composed of fuel tank fuel filter fuel pump fuel inlet line and fuel return line. The function of the fuel supply sys tem is to inject the specified quantity diesel fuel of specified pressure and good atomization into the cylinder at the correct time with definite interval of injection according to the operat ing requirement, and take good com

Using and maintenance of coarse cleaner

1"To tight all the pipe line .

2.Using and adjustment

1) Check the chucking position of the the linkage rod and the accelerator mechanism for rightness and reliabil ity, check the direction of the wire drawing for straight and check on the cornering for smooth transition. 2) The pedal should be depressed easily and to the extreme position

1 stalling wire drawing 2 assembly of accelerator mechanism and pedal 3 front floor of the cab 4 acceleration wire drawing 5 stalling oscillating arm of the engine 6 acceleration oscillating arm of the engine 7 frame schematic diagram of accelerating transmission equipment 26

2"When the DX150Tprecipitator works for 1000/km and 200hours, to wa terproofing.

newest structure of ISUZU truck. It operates simply and reliably and has accelerating wire drawing and hand throttle wire drawing; the pedal is the structure with injected molding and it has the trait of convenient assem

diesel precipitator 27

#6Chassis
7 8Clutch

7!8Transmission 7"8Drive shaft 7#8Rear axle 7%8Frame 7&8Suspension set 7'8Front axle 7(8Steering system 7)8Brake system 7*8Wheel & Spare wheel riser
29

HFC1048
series trucks

1.Brief description of the struc! ture

The clutch equipped for this series truck is single -plate dry type di aphragm spring clutch, outside di ameter of the driven plate is 9254. The hydraulic control unit of the clutch is composed of the clutch pedal oil storage cup release cylin der (master cylinder) wheel cylinder and oil pipe. It is shown in the below figure.

"Clutch

2"Adjust the mas ter cylinder of the clutch: loosen the locknut on the push rod of the master cylinder, ro tate the end of the push rod to con tact gently the with piston of the master cylinder, then rotate the push rod for 3/4 circle in the contrary di rection, tighten the locknut of the push rod, now the clearance be tween the push rod and the piston is about 0.551mm. 3"Adjust wheel cylinder of the clutch

the spherical nut until it contacts with the release fork, then turn back the spherical nut on the push rod for 3 circles, tighten the nut, install the re turn spring of the release fork.

lowed, or else, it can result in the disability of the pedal deficiency of the effective travel and incomplete release of the clutch etc. So the clutch can not work normally. The work of air bleeding should be com pleted by two persons in the best, one person depress the clutch pedal in the cab, the other bleed the air in the wheel cylinder. The schematic diagram of air bleeding for the clutch wheel cylinder is shown . Take off the rubber cap of the air bleed screw on the wheel cylinder,

hydraulic pipeline with brake fluid, then loosen the air bleed screw, air bubble can be puffed from the oil ring if there have air in the pipeline. Repeat the above-mentioned opera tion until the air bubble disappear .

Maintenance and adjustment

Long time use or incorrect adjust ment and incomplete air bleeding of the clutch can bring the halfway re lease of the clutch, let the clutch on the half contact state for long time, aggravate the wear of the clutch pressure plate and friction linings. The decrepitation burnt and exfolia tion of the friction lining, and the burnout of the release bearing also can result in the abnormal operation of the clutch. When maintenance, all kinds of clearance of the clutch must be adjusted. When doing the third maintenance for the trucks ,you must clean general/dispant cylinder and liquid reservoir tank ,then fill grease to hole of disengaging shaft. 31

Take off the return spring of the re lease fork, push the wheel cylinder piston to the bottom of the cylinder, loosen the locknut on the push rod, push the release fork towards the backside of the engine to the posi tion where the release bearing and the release fork contact barely, turn clutch pedal 4"Bleed air from wheel cylinder of the clutch Having air or oil leakage in the hy draulic pipeline of the clutch is unal

Adjustment of the clutch operat! ing system

pedal 5mm. 30

link a plastic pipe on the air bleed screw, put the other end of the pipe into the container filled with brake fluid, depress the clutch pedal sever al times, fill the master cylinder and 1 3 5 7 release fork copper washer wrench container 2 4 6 8 dust cover wheel cylinder soft plastic pipe braking

1"Adjust the limit screw of the clutch (below figure) to make sure that the free play of the pedal is 3 5

HFC1048
series trucks

!!" Transmission

the shifting time, increase the aver age vehicle speed and reduce the working intensity of the driver. The gear shifting operation is accom plished with the shifting control de vice of the transmission, which is shown in the figure on the next page.

shaft is steel cable, the operation of gear selecting or shifting is completed by the pushing or pulling motion of the steel cable. The ball on the flexible shaft and adjusting screw are used for adjusting the total length of the flexible shaft to ensure that the gear selecting or shifting can be to the correct posi tion. There have symbols of each gear on the control handle of the transmis sion, it is shown in the below figure. 1 gear shift control lever 2 dust cover 3 handle 4 floor of the cab 5 flexible shaft for gear selecting 6 transmission rocker arm for gear selecting 7 side bracket for gear selecting 8 flexible shaft for gear shifting 9 fixed bracket of the gear shifting flexible shaft 10 rear cover of the clutch 11 transmission rocker arm for gear shifting schematic diagram of the transmission gear shift control device

3.Using and maintenance

1) If found the gear shifting can not operate or operates difficultly when the engine is not working, it shows that the gear shifting lever (or the flexible shaft) have bad adjustment or the bolt becomes loose, now you must adjust the control lever (or the flexible shaft), check and tighten ev ery bolt and every nut. 2) If found out-of-gear when running on the rough road, the control lever (or the flexible shaft) have bad ad justment, and it should be adjusted correctly. 3) If found free play of the control lever too large, check and tighten every bolt and every nut. 4) Do not take gear shifting operation

when the engine work at over fast speed to avoid accelerating the wear of the synchronizer. 5) When shifting, the force should be gentle. The hand force must be act ed on the control lever until the gear reaches the correct position. Shifting with flap of one push and one loosen is inappropriate and the shifting op eration can not be accomplished easily in this way. 6) Only after the vehicle stop and keep steady, the shifting from driving gear to reverse gear or from reverse gear to driving gear can be done, or else, the gear can be damaged. 7) As the fifth gear is over -speed gear, in order to avoid the damage of the overspeed gear spoke , its 33

1.Brief description of the struc! ture

The transmission equipped for the chassis of this series truck is manual discontinuously variable transmission with fixed shaft gear, and it has five driving gear and one reverse gear. The synchronizer has been equipped on the second third fourth and fifth gear. And the synchronizer is syn chromesh gear system. The synchro nizer for the first gear and the reverse gear is holding mesh gear. Using of the synchronizer on the transmission can make the shifting operation con veniently, decrease the wear and shock on the gear end, extend the service life of the gear tooth, shorten 32

2.Shifting control device of the transmission

The shifting control device of the transmission is long distance soft ca ble type with high floor and short lever, and it take two flexible shaft to imple ment the gear selecting and shifting which is shown in the figure on the next page. It is composed of operat ing lever seat flexible shaft for gear selecting or shifting and the bracket. The core shaft of the interior flexible

control handle of transmission

HFC1048
series trucks

running speed is under 50 km/h, the fifth gear can be used . 8) When running, if find there is ab normal noise in the transmission, stop the vehicle and check it, elimi nate the malfunction. 9) When sliding on the downgrade, stalling of the engine is unallowed, starting the engine with the inertia of sliding on the downgrade is forbid den to avoid the damage of the gear and the synchronizer. 10) In the running -in period of the new vehicle, because the metal chipping which was produced by the frictional function between new parts is bad to components in the trans mission, especially to the life of the conical ring on the synchronizer, so 34

the lubricating oil should be replaced after the running -in period of the new vehicle expires. Under general condition, for every 6000 km running, replace the lubricating oil once. When replacing the lubricating oil, first drain the oil in the transmission, prop up the rear axle, shift the trans mission into the reverse gear, add the kerosene, rotate the transmission for 253 minutes, then drain the kerosene, add the pure gear oil. 11" Check the oil level in the trans mission frequently, if found the level is under the lower edge surface of the oil filler bolt hole, sufficient oil should be added. 12" Check the outside bolt of the transmission and the flange of the

second shaft for tightness and the operating state of the component in the transmission frequently, because the vent plug is blocked by dust and pressure in the transmission increas es, the oil seepage or leakage may be found, so the vent plug should be cleaned periodically. 13" The movement parts of shifting operation should be kept good lubri cating, or else, the shifting operation may become difficult because of the wear of the movement parts. If found the position of gear selecting is in correct, or gear shifting become dif ficult or the transmission is out of gear automatically in using, firstly you should readjust the gear select ing and gear shifting mechanism.

(") Drive shaft

the slide spline and replace the oil seal when necessary 3"The first maintenance ,to fill grease to universal joint ,slide spline ,oil pis tol ,driving spindle and quickly tight the blot in order to sliding the univer sal joint .According to moment ratio to checking and tighten driving spin dle and the middle parts of bearing blots. The second maintenance ,to check ing is there anything fall down about the dirt proof boot ; is there any problems about move the universal joint .when cross shaft in the middle of the needle bearing .The distance would not be very large .If it is too large ,you would be disassemble the universal joint and you can depend

on what you need to changing nee dle bearing universal joint. When you do the third maintenance , should be disassemble the driving spindle .Pay attention to sign on flange ,cross shaft ,link fork, slide spline in order to mounting .When you finished all the maintenances , please do the blance check , the standard of dyramic blance is 2750 r/min.The amount of unbalance is more than 144g.cm&

1.General structure
The two-piece driveshaft, connected with transmission on the front end and with rear axle on the back end.

2.Use & Inspection

1"Driveshaft has been counterpoised

in factory, it should be ensured not to be impacted in use and not to be knocked and stacked in disassemble and carry. Replace if the shaft is dis torted or the balancer is desquamat ed, otherwise there will be vibration, noise, and extra impact in travel, it can damage power train and endan ger driver. 2"Regularly check the cross shaft needle bearing, check the sealing of

!IV" Rear axle

The brief of structure #Single reduc

tion rear axle ,as the final part of power train of truck ,is the driving axle ,and it is composed of final drive and differential and axle hous ing .Final drive can not only change 35

HFC1048
series trucks

the direction of driving force ,but also reduce the rotate speed .It is com posed of drive pinion and driven gear and final drive .The drive pinion is composed with drive shaft ,whose end with spline is connected with uni versal joint assembly by coupling flange .Center support is mounted in two opposite conical bearing ,so that it can suffer not only radical bearing , but also axial force. Drive pinion, whose small-end journal mounted in direct tapered roller bearing, can on ly support radial force. It is fixed on the flange which located on top left of differential case by several bolts. A differential, composed of differen tial case and cross and four side pin ions, let the left wheel rotate at a dif 36

ferent speed from the right wheel. Rear one -piece banjo style axle housing is made by means of weld ing punched armor plate. Meshing of tooth face and clearance adjustment of final drive (1) Check drive pinion bearing for pretension .The pretightening force of drive pinion bearing should be ad justed. Measuring in the bolt hole of drive pinion bearing case, the tan gential pull should be 15~30N. (2)The pretightening force of drive pinion bearing can be adjusted by means of adding and reducing ad justing shim. Add shim can decrease friction torque, while reducing shim can increase it. There are three kind of shim according to thickness

(0.40mm, 0.45mm, 0.5mm). (3) Check final drive for meshing be tween drive pinion and driven gear. The contact area and side play be tween drive pinion and driven gear can be adjusted by means of adjust ing shim and adjusting collar of dif ferential bearing. There are three kind of shim is 0.30mm and 0.4mm 0.45mm, and the 0.5mm Normally, the clearance between these two gears is 0.15~0.25mm, while the side play ranges under 0.07mm. To adjust side play, measure four points with equal angle around the driven gear, and the gauge outfit of micrometer should be in a vertical position. To adjust tooth contact area, driven gear should be coated with red lead at

three points, and 2 ~3 teeth should coated at every point. Then rotate gears clockwise and anti -clockwise to get the trace of contact area (see the right figure). The teeth area is not suit the figure (a)which should be adjust it .If the trace is slanting to the convex or concave then adding the shims ;if the trace is slanting to the convex or concave ,then reducing the shims. Normal trace should be near the small end ,as figure (a):Add shim if trace near the convex or concave tooth root ,as figure (b)'Reduce shim top , as figure (c). Adjust the wheel hub bearing of rear axle: to locking bearing and nut ,then if trace near convex or concave tooth

release1 : 3%1 : 4circle& Tighten the force moment to 490%588N.m

and bearings of final drive, for they have been matched and adjusted in factory. Do these only when gear worn and free play is beyond the limit value, or when bearing axial clearance is beyond the limit, or when some of parts damaged. 3"Clean the vent plug regularly, make sure that ventilation is expe dite. A jammed air drain can bring higher air pressure in rear axle, and it will result in lubricant leak from the

Use & maintenance

drive pinion seal and other welding line. 4"Check the lubricant level in axle housing regularly. Check the lubri if the chroma and viscosity is abnor mal. 37 cant for quality regularly, and replace

1"Lubricate for hyperbola bevel gear is very strict, can be only specified gear oil. Don't use or mix with other gear oil, or will result in quickened scratch and wear. 2"Don't remove or adjust the gears

HFC1048
series trucks

5"Finished the third maintenance,

overweight , parking position and road and so on. .So ,must following the request to driving .

2. Use & Maintain leaf spring

1)At the beginning of running-in pe riod, check the nut on U -type fas tening bolt and tighten it with speci fied torque when trochometer points to 200km and 500km. 1. 3. 5. 6. Front leaf spring 2. Front U bolt bumper 4. Front shackle Upper bracket of front suspension Front absorber 7.nut front suspension assembly 2)After running-in period, tighten the nut on U -type fastening bolt with specified torque (with vehicle fully loaded). Do it also when leaf spring is replaced or reset. 3)Tighten the nut on U-type fasten ing bolt with specified torque (with vehicle fully loaded) every 2000 ~ 3000km. 1 3 5 6 Frame 2 Rear leaf spring Rear center bolt 4 Rear absorber Secondary spring bracket Rear shackle clamp rear suspension assembly 4) The first maintenance$Check and tighten bolts and nuts in your touch on suspension. Check the rubber parts on the suspension and replace

if too much wear. 5"At the second maintenance, doing the first maintenance items .Then disassemble and lubricant the spring of plate , at the same time to check ing anti-roll stabilizer . 6"At the third maintenance, doing disassemble all of the rubber to changing the news. 7)Take notice of the orientation when replace leaf spring or operate on the center bolt. Tighten each nut first, then tighten nuts on front U -type fastening bolt with specified torque before tighten the rear ones. the second maintenance items . Then

road surface (commonly more than 10km). Absorber don't have resis tance if the temperature lower than condition temperature; if one ab sorber have much lower temperature than the symmetrical one, the lower one's resistance is much more smaller. Lower resistance result from lack in oil or from damage of some important part, and the absorber that lack in resistance should be removed to inspect. 2" Check the absorber for oil leak if continuous abnormal vibration is de tected. Oil leak should be dealt with on time, so that the absorber can work normally. 3" Check absorber when maintaining vehicle. To check absorber, stick up 39

disassemble the back cover .Then clean cavity and main reducer axle . To tight the fore moment nut and blot.

!&"Suspension set

!V"Frame

General Structure: The suspension of this series of trucks is composed of multiply variable leaf spring bidirec tional hydraulic telescopic shock ab sorber and transverse stabilizer. Rear leaf spring is composed of main spring and secondary spring, its stiffness changes little by little, so that vehicle is more comfortable for ride.

The brief of structure :This kind of truck's chassis is across structure Use & Maintenance :Using longitudi nal beam and cross beam is to fixed the frame .Using weld and screw thread to connecting .So ,keep all the parts well to exerting the advantage of the frame .When doing the third maintenance checking , if the screws are lax that should be tight it. If the cross beam have something wrong , should be mend it . The reason of damage the frame is 38

3. Use & Check absorber

1" Check the absorber for tempera

ture after running a length on bad

HFC1048
series trucks

it and hold its lower end by vise, then pull and press it for several times. Normally the resistance is bigger when pulled, otherwise the absorber is damaged or lack in oil. In the case , to changing and mend ing the parts ,then fill oil into shock absorber .In order to absorber parts. 4" Always replace the oil seal when you replace absorber rod. Don't dis necessary. 5"At the third maintenance ,disas semble the shock absorber and changing the new oil .Do not clean the shock absorber. assemble parts such as valve if un

front axle, steering knuckle, steering knuckle king pin, hub and tie rod. See the next figure. The front axle is I -beam. The toe ing-in is 3~6mm (diagonal tire) and 1~3mm (radial tire). Proper orienta tion can make sure the vehicle stable and easy to control, so that can lessen driver's fatigue and slower tire wear.

2. Adjustment
1) Adjustment of front hub bearing. To adjust front hub bearing in axial retightening force, tighten fastening nut with wrench, and loosen knuckle nut for about 120o. Rotate the hub clockwise and anti -clockwise, make sure that roller against the tapered face of bearing outer race properly, then tighten nut to the position where the rabbet aims the split pin hole. Check the hub if it can rotate freely and don't swing a lot. Now, distort the split pin and fix it. 2) Adjustment of clearance between

ing-in can be adjusted via adjusting tie rod. Park the vehicle on a flat ground, jack up its header and orient front wheels just as vehicle run for ward. Loosen locking nuts of tie rod, rotate the tie rod utile the toeing-in fit the specified size.

3) when doing the third maintenance ,to disassembly the front axle then cleaning and checking it. a) If the distance between steering knuckle and front axle is very large , should put a thrust shim on it to ad justing .The distance is 0.1mm to be good. b) When the steering knuckle pin and the bush's distance is 0.15mm, then to change new ones.The dam age distance of the steering knuckle pin is to 0.07mm,changing new ones. c) The damage of steering drag rod ball end and ball end is too big ,then change the new ones. d) When find out the damage of oil seal of the wheel hub , then change the new ones .

!("Steering system
steering system.

General Structure#The steering sys

tem of this series of truck is power

Power steering
The steering system composed of steering control mechanism, linkage mechanism gear power pipeline. The energy source of the steering system is depended on driver's physical strength and power of en gine .In some emergent cases about steering system that the driver can control the direction .To compare with some common machine steering system , the power steering system is very sensitive and secure. 41 whole power steering steering pump and

Use & Maintenance

1) The first maintenance .When doing the first maintenance ,check the nut tightly. 2) When doing the second mainte nance to checking damage about steering knuckle , steering knuckle arm ;to checking about steering knuckle pin bearing ;to checking about the drag rod .According to the regulate ,disassembly wheel hub and fill grease with it.

!'"Front axle

1. General structure
Front axle assembly is composed of 40

1 3 5 7

Front hub 2 Brake drum Steering knuckle 4 King pin Pitman arm 6 Front axle Tie rod front axle assembly

knuckle and front axle. The clearance is adjusted via adjusting shim, it should less than 0.1mm. 3) Adjustment of toeing -in. The toe

HFC1048
series trucks

Operation Inspection for Steering Mechanism 1) Put front wheels on a swivel table. 2) Rotate steering wheel clockwise and anti -clockwise to its limit posi tion, to detect if it is fluent. 3) Let engine run in idle speed and check steering wheel for free play. The limit value of this free play is 15~ 35mm. Rotate the adjusting screw clockwise to decrease the free play, while rotate anti -clockwise to in crease. 4) When engine run in idle speed, the torque of steering wheel should be around 19.6N. 5)When staring the engine to turning steering wheel to two sides for sever al times .When removing the air from 42

the engine ,then fill oil into it. 6"Turing the steering wheel to the front. 7"Turn off the engine to checking oil. If it need oil, then fill it. Note:To checking is steering oil on a high temperature .If it has some trou bles, then doing the 4 and 5 steps again or mending power steering pump.

tion to the oil pump pipeline ,it can not fill with air in it .keep cleaning it. Step: a) Turn the steering out oil pump into the steering in oil pump. b) The return oil inlet connect with oil can inlet. 4" In some troubles of power steer steering but could not use for a long time. 5" Don't steer when parking, since it will shorten useful life of parts. 6" According to the regulate to fill hydraulic pressure oil, the environ change steering system ment temperature is above 0 4 , should adopt L -HM 464# wear resistance hydraulic pressure oil; the environ ing, the drive can use the hand

ment temperature on 0 4 . (the dif ferent number oil can't mix an us age).The import power steering or steering pump to choose to press oil with the DEXRONII model number liquid.(American G.M. standard)

The main idea is to prevent ,to check for scheduled time .Following about the ministry of communications stan dard about the car JT : T201%95(The arts and crafts maintenance of car) CJl7%86 and city build ministry standard mending way of the city bus). (The technique condition

iii. Check tight each conjunction part. iv. Check pipe conjunction part, in sured and don't leak oil . c)Second class maintenance(1000015000 kms) i. Chang the power steering oil. ii. Clean and check the steering wheel. iii. Clean the power steering oil net. Iv Check front axle, ball axle, steer ing knuckle, steering knuckle arm, steering knuckle frname. v. Disassemble, length pull rod, cleaning and checking parts in order to insure them well. vi.The other parts, please read the reference. (JT : T 201%95 ) d)To install steering knuckle plumb ing arm and locate blots. The daily 43

The use and maintenance of power steering

1)How to use of power steering a) Don't steer when parking for 5 minutes. b) Forbid to steer the steering wheel when can not moved. c) Forbid to steer the steering wheel in the same place. d) Forbid to steer the steering wheel speed for 90turn/m. 2)How to maintenance of power steering

a)Daily maintenance: to checking the truck when driving in order to your security. b)One class maintenance(2000-3000 kms) i. Each lubrication partto fill the grease, the power steering should be fill the oil on time. ii. Insure cross shaft , cross/lax pull rodten ball end to moved vivid and not loose.

Use and Maintenace

1" Check the new truck to driving for and cleaning oil net.

3000%4000km ,then fill oil to steering 2" Always checking the oil measure or oil quantity in the oil crock, if it has something wrong that change it . 3" Do not disassemble the steering system for another side .Pay atten

HFC1048
series trucks

maintenance: i. Insure the location. Find out steer ing knuckle plumbing arm is fall, then put them on. ii. If the steering knuckle plumbing arm have some mistake, change the new ones. iii. Tight the steering gear and frame, frame and frame blot. iv. When turning the direction, insure the length pull rob and steering knuckle plumbing arm do not inter vene for each other.

1. Running brake system 1.1 Air brake

1) Brief description of this system: Compared with hydraulic brake, air brake can bring greater braking force under the condition that force on the pedal is not great and the pedal stroke is not long; at the same time, dual-circuit air -pressure driv ing braking device is equipped to front and rear wheel separately, so the braking is safe, reliable, labor saving, and more effective; even if one of the brakes does not work, the vehicle can still brake safely. 2) Structure and theory (referring to the following diagram) Brake pipeline is arranged as fol lows: compressed air produced by

air compressor 1 comes into the main air reservoir 3 (namely wet air reservoir); and then the air is separat ed into two and come into the front chamber 9 of the auxiliary air reser voir and the rear chamber 4 of the main air reservoir, the front chamber 9 of the auxiliary air reservoir and the rear chamber 4 of the main air reservoir. Compressed air in the front chamber 9 of the auxiliary air reser voir and the rear chamber 4 of the main air reservoir come into upper and lower chambers of brake valve 8, and then the air is transported separately to rear brake chamber 12 and front brake chamber 2. Check valves 10 installed on ends of the air inlet pipes of the front chamber 9 of

the auxiliary air reservoir and the rear chamber 4 of the main air reservoir in case that compressed air in the air reservoir flows backwards. There are interfaces for air pressure gauge 7 and pressure -adjusting valve 6. When air pressure reaches 0.74 0.84Mpa, compressed air props up valve of the pressure -adjusting valve, and comes into upper cover of the air compressor to make air inlet valve open and the air compressor idles. When brake valve 8 is de pressed, front and rear brake cham ber 2 and 12 operate at the same time, which makes front and rear brakes operate. When the brake ped al is released, compressed air in front and rear brake chambers go in

to the atmosphere by front and rear air-deflating valves 11 and 13.

Interface for air inlet Interface for low pressure Interface for clutch

!IX"Braking system

Braking systems of trucks of this se ries are: parking brake system(center drum) and running brake system (air brake, hydraulic brake)

1. air compressor! 2. front brake chamber! 3. front cavity on main gas cylinder 4. rear cavity on main gas cylinder! 5. safety valve! 6. pressure control valve 7. barometer! 8. brake valve! 9. additional gas cylinder! 10. one-way valve 11. front quick-release valve! 12. rear brake valve! 13. rear quick-release valve 45

44

HFC1048
series trucks

Brake assembly
The function of brake is to utilize power produced by friction between brake drum and brake shoe slice to absorb kinetic energy of vehicle to decelerate or stop the vehicle. Front and rear brakes of this brake system adopt imbalanced structure and are mainly composed of brake chamber, brake arm and brake

Adjusting arm
adjusting arm,

1"Lubrication: mount oil month on use lithium base grease periodically to lubricate ad justing arm (maximum lubrication in terval is limited to 10000km), or else, life of adjusting arm will decrease. 2"Check adjusting arm's counter! clockwise force moment periodically: rotate adjusting nut of adjusting arm counterclockwise when running every 20000km and measure whether the rotary moment is bigger than 18Nm, measure for three times repeatedly. If the moment is smaller than 18Nm, it indicates adjusting arm has been damage and needs to be replaced the adjusting arm assembly.

Brake
Front brake has the same structure with the rear brake. It is shoe brake with camshaft with fixed sustainer. When braking, front and rear shoe slices of the brake press to the rotat ing brake drum by the action of the same push force; so the rear brake shoe is called power-reducing brake shoe. All above lead to imbalance of forces that front and rear brake shoes press on the brake drum, so this kind of brake is called simple imbalanced brake. Clearance between friction disc of the brake shoe and the brake drum must be proper, before adjusting the clear ance, make the front wheel off ground; adjusting steps are as follows:

Full adjustment
1. Loosening fixed nut of brake shoe bearing pin and nut of binding bolt on cam bracket. 2. Rotate brake shoe bearing pin so as to make clearance between front shoe and bearing pin end the same as that between rear shoe and bear ing pin. 3. Start braking, make brake shoe friction disc lean against brake drum closely and brake camshaft auto matic positioned and tighten nut of binding bolt on support frame. 4. Release braking and rotate worm so as to make brake shoe friction disc lean against brake drum closely. Then counter -rotate worm, released by 3/4r, brake drum should be rotate 47

1. return spring locating pin' 2. roller shaft-brake shoe shaft' 5/18. front brake shoe with liner assembly'

3. roller-brake shoe' 4. gripping ring-brake shoe roller 10. hex bolt' 11. front brake air chamber support frame with liner assembly' 12. front left brake air chamber assembly' 13. hex bolt' 14. front brake adjusting arm assembly' 15. shoe shaft fixed bolt' 16. front brake shoe-shoe shaft' 17. front and rear brake shoe shaft-liner' 18. return spring 46 6/19. front brake friction plate' 7. brake cam' 8. front brake baseboard with liner assembly' 9. front brake dust cap'

HFC1048
series trucks

freely. 5. Test drive after adjustment, check working condition of brake, whether the brake drum get hot and whether braking distance is proper. If not, readjust it

Brake valve
Brake valve is to adjust and control the whole brake system. Use and maintenance 1)Take care of it a) Should check the tube pressure before driving, be air pressure mea sure is 0.6 MPa square can drive, while driving in normally is in the O. 74 - 0.84 MPas,should park the car whether leak air or not and whether the compressor normal work or not. b)When driving the truck to check brake system. If it has something wrong should be change it for an other one. c)The damage of the brake shoe plate is too big, then changing an other one. The piece should be the

same new ones and do not have dirty oil, shatter, chap. d)To change the friction and install shoe plate and brake cam again in order to adjusting the friction piece and the brake cam. 2)Shedule time maintenance: a) The first maintenance (1500-2000 kms) i. To excluding the oil from the gas cylinder. ii. To fill with grease where need it. iii. To checking and adjusting the tighten about air compressor . b) The second maintenance(10000% 12000km) i. Disassemble and adjust the brake and adjust the distance between brake shoe friction piece.

ii Check the air compressor and clean the dust of air valve. iii. Check the brake involucra which needs news to changing it. c) The third maintenance (24000% 30000km) i. Check and adjust the brake valve . When it need new one then change it ii. Check the brake valve pipe . When it need new one then change it iii. Clean all the pipe in order to keep it liquidity.

1.2 Hydraulic brake system

booster, vacuum cylinder, master cylinder, control mechanism, brake tube, front brake and rear brake. It is sensitive and reliable, and it is sim

connect to engine vacuum pump

ple to manipulate. See the last figure. If you feel braking power is not suffi cient when brake pedal is depressed completely and oil level is normal, there may be air in brake system. Bleed system in follow sequence. Firstly, bleed RR brake; secondly, bleed LR brake; thirdly, bleed RF brake; then bleed LF brake. Follow these steps: a. Clean air -drain screw of main cylinder and wheel cylinder; b. Remove oil -drain plug of main cylinder or reservoir and fill it with brake fluid until fluid level reach the 49

Parts checking
To move the worm of brake arm to adjusting the distance between brake assembly and brake drum . The way# to the worm for clockwise and move it again and again when it couter -clockwise to 1 : 2%3 : 4circle. can moved.Then move the worm for At last the drake drum work agility . The distance between brake friction piece and brake drum is 0.25c% 0.4mm$camshaft is 0.45mm.

1 2 3 5 7

Control mechanism Vacuum booster Master Cylinder 4 Reservoir Vacuum cylinder 6 Brake tube Front & Rear brake the picture of running brake

1) General Structure The running brake system is hy draulic. It is composed of vacuum

48

HFC1048
series trucks

edge. c. Depress the brake pedal several times before hold it depressed and release the air-drain screw to bleed. Repeat doing this until air in tube be bled completely. Keep a little oil left, or air can reenter the system. d. Fill reservoir with brake fluid. 1. Brake pedal 2.Vacuum booster and main cylinder assembly 3.Reservoir 4. Connection hose 5.Rear brake 6.Vacuum cylinder 7.Intake manifold 8.Front brake 9. Vacuum check valve 10.Connect to vacuum-alarm %hydraulic tube %% vacuum tube schematic diagram hydrostatic brake system

2) Note When Use Brake Fluid ) The specified brake fluid of this series truck is synthetic brake fluid of class JG3 (GB10830). * Never use mixed brake fluid. , Synthetic brake fluid is good at sopping up. They should be storage in a clean sealed dry container, keep away from water, organic solvent, petroleum, and dust. Otherwise the vehicle's capability of brake would be cut down seriously. - Clean system with alcohol before replacing brake fluid with different brand. Follow these if alcohol is un available. a. After drain all old brake fluid, fill reservoir with new fluid near to the opening and bleed system again, in

order to sweep old fluid away. b. Fill system with brake fluid. . Brake pedal's free play should be 5 ~8mm after adjusted, or it will cause main booster work abnormally and make brake drum over hot.

Jack up the wheel which you want to adjust and remove the seal plug. Dial the adjusting gear of wheel cylinder piston accord the arrow near the ad justing hole on bottom plate with special adjusting screw and at the same time rotate the brake drum until the drum can not rotated by hands. Then rotate the adjusting gear back for 5 ~9 teeth, keep the pad 0.2 ~ 0.45mm away from the drum, so that the drum can rotate freely again. 3) Use & Check Replace the pad which is worn out or damaged. Before installed, the new pad should be ground. Make sure that the new pad has not oil coat, al so has not crack and chap and other flaw.

The clearance should be adjusted in every time of maintenance. Check drums with hands for temperature ev ery time you park, adjust the clear ance if the temperature is too high. Check wheel cylinders for leak, and replace the leather gasket if leak is detected. Protect drums from being wrong result from over heat and oth er reason.

Running brake
1) General Structure The running brake is hydraulic drum, both front and rear is two leading shoe brake. It is composed of bottom plate, wheel cylinder, brake shoe set with pad, and return spring set. 2) Adjustment of Running Brake The clearance between pad and drum will be bigger and bigger due to wear. In order to ensure brake work well, adjust it regularly follow these steps.

Vacuum booster
1) General Structure Booster of this series of truck is dual diaphragm vacuum booster, which is composed of return spring, control valve, rubber diaphragm, noise elim ination board, and so on. 2) Adjustment Booster have been adjusted in fac 51

50

HFC1048
series trucks

tory, don't disassemble it and protect the diaphragm from been damaged.

is parking. Also it can operate with running brake together in emer gence. 2) Adjustment Normally, the clearance between parking brake drum and brake pad is 0.65mm, and it is homogeneous in upper and lower parts. The pad should be replaced often. Follow

Then return the adjusting nut for 2~6 teeth. See the right figure.

1.3 Parking brake system

! * "Wheel & Spare wheel riser

General structure#Every truck has tyre. Use & Check: In order to use for a longer time, please charge tire according to specified pressure value. Never drive when pressure is insufficient. It is normal it by that pressure Check increases the tire during travel, and don't try to reduce deflating. seven wheels, one of which is spare

before installed. It should be talced on the surface between inner tube and outer tire. Wheel nuts should be tightened for two steps. Tighten all of them first before tighten them with specified torque according to diag onal sequence.

2. Spare wheel riser

1) General Structure & Use The spare wheel riser is driven by catenary suspension internal geared wheel, see the next figure. It is mounted underneath the frame. To operate it, fix it on the frame and tighten it with hand before rock back for 15 degree. 2) Maintenance of Riser Check riser for loose every time before drive. Check chain and carrier spring for crack and replace if necessary. In order to prevent it from rust, grease the gearing regularly, so

1 Control lever 3 Frame

2 Pull wire 4 Parking brake

these steps. a. Jacking up rear axle until one wheel deviate from ground. b. Release the brake handle com pletely, shift gears to neutral position. c. Rotate brake drum until the hole gets its lowest position. Insert a screwdriver through this hole to stir the adjusting nut upward until brake drum braked completely adjustment of the clearance between brake pad and drum Use & Check: Check and adjust the clearance between brake pad and drum.

parking brake system control mechanism The parking brake system includes control lever, pull wire, and parking brake, as the last figure. Parking brake, which is mounted next to transmission, is center drum brake. It can act on drive shaft when vehicle 52

pressure when tire is not hot. If the two center patterns on tire tread touch against ground under fully loaded, the pressure is normal. Clean the rust and other dirty on rim In order to make tires wore uniformly, exchange wheels each other according to the figure.

that it can be easy to operate. The third maintenance, should be prepare wheel.Then cleaning,checking ,install it again. 53

HFC1048
series trucks

IV6Electrical equipment
( ) Starter

(!) Generator and adjuster (") Illumination equipments (#) Battery

1 Frame 2 Spare wheel riser as

(%) Sensor

sembly 3 Eccentric wheel 4 Spare wheel 5 Chain 6 Carrier spare wheel riser set

54

55

HFC1048
series trucks

( )Starter
Note: 1) Starter should be connected with battery correctly. 2) Every time start, don't keep starter work continuously for more than 15s and stop for 1-2 seconds in the in terval, since over hot may damage it. Rest it before try start once again. 3) After several continuative failures, check starter, solenoid switch, bat tery, wires, and also oil supply sys tem. Retry after trouble is shot.

should be matched properly. 2) Never check generator by short circuit fire wire and magnetic field. 3"The diode and insulation of gener ter and ohmmeter. Don't ator can be inspected with multime use megohmmeter to inspect, also AC power whose voltage exceeds 200v.

on the high lamp to lighten the road, but switch to low lamp when two ve hicles pass each other. In order to see the road clearly , when you stripping and re-assembly headlight that you sould be adjuste ment the position . The way is to put the car on a evenly road then put a screen in front of the car. The dis tance between the car and the screen is about 10meters.(as picture)
Left Right 10 m Left Right Screen

(") Illuminate equipments

1. Headlamp

This series of truck have two head lamps which are embedded in front of cab symmetrically. The headlamp which is called double filament bulb has two different pieces of filament and can shine two different kinds of ray, the brighter one is used as high lamp while the dimmer one is used as low lamp. Running in night, turn

for a line, from measuring cell screen to testing left, right, the far and near light beam to project light upon di rections to be partial to move a value respectively. To adjusting the headlight' the up headlamp(old series) Use the measuring cell to testing. rightess and the level. To adjusting the passing beam , make it match di agram the shining area center re

quest a left and right light to left and right (the V is left-the V is left, the V is right -the V is right for the middle point) be partial to move a value to be no bigger than a 100 mms.

(!)Generator and adjuster

Note: 1) Generator should be connected with adjuster correctly, and the po larities of generator and adjuster

2. Small light
Two small lights are embedded on the two symmetrical corner of front panel. They should be turned on 57

headlamp(new series)

Put the car and the measuring cell

56

HFC1048
series trucks

when vehicle park in dark or fog, al so when run in day to show the posi tion and the width of the vehicle.

The battery of this series is aneroid, and it is sealed by a plastic case. This kind of battery has a big capac ity and a light weight.

Never fill battery with fountain or river water, for them will do harm to it. 4)Check the electrolyte for specific gravity and level. Do it every 10 ~15 days in winter, while do it every 5~10 days in summer. Specific gravity is measured with gravimeter. Table 1 shows normal specific gravity of electrolyte. 5)The battery should always being charged. Check battery for electrical voltage if engine is hard to be start

pacitance into battery. Cut down the charging current for half after single cell's voltage reaches 2.4V. After charging battery for 3~5 hours, if the specific gravity of electrolyte don't rise any more, keep on charging for 2 ~3 more hours. Table 2 shows the relationship between temperature and the corrected specific gravity value of electrolyte. 6)Protect the joint of terminal post and wire from dirt and loose, or the terminal post will be burnt. Applying a Vaseline coat on the terminal post after tighten the joint which can pro tect joint from rust and loose contact, so that engine can be started easily. 7)If left unused for a long time, bat tery should be removed and pre

served in a place where is dry, shady, cool, and ventilative And do the additional charging every month. Table 1 Specific gravity of electrolyte Specific gravity of fully charged bat tery under 154 Winter Summer Where temp below -404 in winter Where temp above -304 in winter Where temp above -204 in winter Where temp above -104 in winter Where temp below 04 in winter Table 2 Measured temp of electrolyte Corrected value on hydrometer 1"310 1.290 1"280 1"270 1"270 1"270 1"260 1"250 1"240 1"240

(%)Sensor

1. Fuel level gauge sensor

The fuel level sensor is sliding re sister. Floating on the fuel level, the float rises and drops with the level's change. This change causes the re sister connected in circuit and short ed, and make the electromagnetic fu el level gauge changes. Connecting the fuel level alarm lamp's terminal with the indicator light can shows the lowest fuel level.

3. Fog lamp
Fog lamp can light further in fog than other lamp. They should be turned on when vehicle run or park in fog or in dark, so that vehicle can be seen clearly. Fog lamp is combined with headlamp.

2. Use & Note

1) Keep the case clean, and protect battery from leak.

Loca

4. Ceiling lamp
The ceiling lamp is installed on the ceiling, and it is combined with in side rear mirror together. It can light en the cab, and also it can observe the condition behind. 2) Make sure that the hole on the upper cap not choked, or the plate will be damaged by the vapor pro duced own to electrolyzing. 3)The electrolyte level should be 10~ 15mm higher than plate. Only dis tilled water can be filled into battery.

ed. Additional charging if it is detect ed that specific gravity of electrolyte lower than 1.18 ~1.20, or battery plates will be vulcanized and it will do harm to the plates. Additional charging should be held for 13 ~16 hours, and it can breathe 1/10 of ca

Corrected specific gravity

2. Water temp sensor

The temp sensor is a thermistor which is mounted in water jacket to detect the temp of cooling water. It is connected with the water temp gauge on instrument board. The wa

value of electrolyte under 15$ +454 +304 +154 04 -154 -304 -454 +0.02 +0.01 0 -0.01 -0.02 -0.03 -0.04

(#)Battery
1. General
58

59

HFC1048
series trucks

ter temp sensor has a negative tem perature coefficient and its resistance decreases with the increase of water temperature. Don't replace the sen sor with a positive temperature coef ficient one, or the water temp gauge can not work correctly.

% Vehicle service and maintenance

( ) Notice during running-in period (!) Daily maintenance (") Second-class maintenance (#) Seasonal maintenance

3. Oil pressure alarm

Oil pressure alarm is a normal closed switch. It will be opened when oil pressure reaches and over the low est pressure, so that circuit is dis connected and indicator goes out.

60

61

HFC1048
series trucks

!I" Notice during running in period

economical efficiency and also to use it longer, follow these during running-

lamp

instruments

for

correct

1)Put so many goods in the trucks ,it will be curtail the car's life and also influence your safety. 2) Don't run faster than the follow speed. First gear Second gear Third gear Forth gear Fifth gear 7km/h 14km/h 26km/h 40km/h 56km/h

well. Don't drive in high speed when the temp is below the normal temp (between 80oC and 90oC). 5) Regularly check the engine cylinder cover, wheel nuts, car body, and the U -bolt of leaf spring for tighten. Check the steering system, brake system, and clutch for normal operation. Check steering wheel for free play. Check the brake pedal and clutch pedal for operating stroke and free play. Note: Cylinder cover bolts should be tightened twice when the cylinder is cool,according to diagonal sequence from the center to sides. 6) The oil should be replaced after 500km 1000km 2500km (do it when engine is hot), then it will be repl -

aced again in second -class main tenance.

service for the truck. As a result of the area and periodical service are different, so you should be take care of the truck to periodical service. The following references is how to take good care of the chassis. Does not introduce about the season service.User can follow the basis about area to do season service. Everyday routine maintenance Everyday you do not use the truck , you may check about it, in order to having a good technology. 1.To checking the engine and fill with rust prevention and antifreeze oolant. In winter,let out water from the engine.If you want to using antifreeze coolant that you must follow the air temperature. 63

operation, and check brake system for normal air pressure. 5) Check the shift gears for right; the control parts for normality, transm ission for shifting smoothly, and the indicator should works correctly. 6) Check tires for proper air pres sure. 7) Check that if driver tools and accessories are taken.

To improve vehicle's reliability and

3. After running-in period

1) Replace engine oil and oil filter core. Replace oil in transmission case and rear axle, and replace lubrication in steering gear, also hub bearing grease. 2) Check all external bolts and nuts with specified torque. 3) Apply grease on all points where should be lubricated. 4) Do items of first -class mainten ance.

in period which is specified as about 2500km.

1. Before running-in period

1) Wa sh vehicle with water, and check all bolts and nuts for tighten. 2) Check the radiator for enough water,and check the engine,transmission, rear axle, and steering gear box for enough lubrication,also check battery and reservoir for liquid level. and steering system for 3"check brake system drive system, operation. 4) Check electrical equipments and 62

3) At the beginning, check the rear axle, transmission case, driveshaft, and brake drum for temperature. Give ear to the sound of chassis when driving and stop to inspect if abnormal noise is heard, then shoot trouble before drive again. 4) Both the cooling water temp and oil pressure should be noticed very

2. During the running-in period

1) The new truck should run on smooth road, and don't make it load more than 50% of its rated load before it traveled 800km and don't load more than 75% before 1500km, or it will shorten truck's life and bring driver danger.

!!"Daily maintename

When you find out some mistakes about the trucks, you must check and resolve it at the first time. It is very important to do periodical

correct

HFC1048
series trucks

2.To checking the measure lubricant oil of the engine. 3.To checking the degree of tension and measure of injury about the fan belt. 4.To checking brake system when it was working or sealing the atmospheric pressure (hydraulic pressure) and pipe line. 5.To checking the work about direction system circumstance,

nut. 8.Notice to fill water to the air reservoir everyday.

of technique and work request, do seasonal maintenance. At the beginning of summer: 1. Cleanout water scale in the coolant system. 2. Replace lubrication for summer. 3. Fueling with #0 diesel oil specified in GB252. 4. Clean up the battery and adjust the specific gravity of electrolyte. At the beginning of winter: 1. Clean up the battery and adjust the specific gravity of electrolyte. Then remove and charge it. 2. Install cold proofing devices, also kid preventation devices if neces sary. 3. Fueling with #10 diesel oil speci fied in GB252.

& Trouble shooting

1+Electrical parts trouble shooting 2 Clutch trouble shooting 3+Drive shaft trouble shooting 4 Transmission trouble shooting 5 Front axle trouble shooting 6 Rear axle trouble shooting 7 Steering mechanism trouble shooting 8 Running brake trouble shooting 9 Parking brake failure shooting 10 Suspension set trouble shooting 11 Wheel trouble shooting
65

( " )Second -class mainte nance

When the ne w car was driving for one period which should take daily care and scheduled care.In order to understanding the basis usage and the technology.The car drive on a common road,the second mainten ance mileage is 15000 kilometers. The car is going to do the second maintenance,you can come to JAC Special Repair Shop and we will try our best to help you.

whether each bolt and the nut hasn't loosen to move.The cotter pin is very tight. 6.To checking weather the spring about armor plate 7.To checking the atmospheric pressure of wheel.To finding where is harmful position about the wheel and 64

!#"Seasonal maintenance

In order to keep some parts meet the requirements of climate on aspects

HFC1048
series trucks

Being used, the vehicle will often be broke along with it travels longer and longer. In order to recover vehicle to normal proper situation, also to pro long its life, the trouble must been find out and then been disposed in an effective way. * To shoot troubles of engine, see Engine Operating Instruction Manual which every vehicle have been e quipped.

fuel-gauge still motionless, it means the fuel-gauge to break down. The hydraulic indicator isn't bright: Dismantle hydraulic -pneumatic alert machine bottom, and take it iron. If the hydraulic -pneumatic indicator is bright at this time, the elucidation is hydraulic -pneumatic to report the machine switch damage, should re place. If still not bright, explain the index sign lamp bulb burn bad, should replace, perhaps is launch the engine oil road contain break down. Dynamo is not work Dynamo is work well, but indicator light is not work.The main cause of lamp connection is not well.

1+Electrical parts trouble shooting

Trouble symptom and probable cause (1)Not start (a)Incorrect connection (b)Barry output Incorrect connection (c)Lubricant is not the standard. (d)Start the relay is incorrect. (d) Clean the battery (b) Clean and tight it (c) replace lubricant (d) repair and replace Checking and remedy

Checking and remedy of electri! cal system fuel gauge not move
Spread fuel-gauge and take it iron, if the fuel -gauge needle point toward fuel-gauge have already break down or the instrument fuse was burn out, should check to fix or replace. If the 66

(2)Insufficient electric capacity (a) New battery without circulation of charge and dis charge, or not been charged to rated quantity. (b) Generator without charge or enough charge. (c) Damaged pole plate. (d) Low level or improper specific gravity of electrolyte

(a)Charge as specified (b)Check connections and repair (c) Check and repair (d)Fill up electrolyte and charge battery with it separated from vehicle 67

HFC1048
series trucks

2. Clutch trouble shooting

Trouble symptom and probable cause Checking and remedy Trouble symptom and probable cause Checking and remedy

!3"Too much waste of electrolyte

(a) High charging amperage. Elactrolyte vaporize or ov- !a"Reduce the frequency of starting and shorten the start ing time .Decrease amperage of charging current erflow (b) Leak battery !b"Replace cover of the battery.

(1) Shaking clutch a. Overloading too much vehicle b. Not start in low gear c. Defective release bearing or insufficient oil d. Corrugated fin cracked, friction lining worn, loose rivet, damper spring broken, or damper fin broken down.

a. Load by rated load b. Start in first gear when loading much c. Clean, lubricate or replace d. Replace

!4"Self-discharge of battery

!a"Battery output cable short to ground !b"A short circuit between pole plates !c"Damaged or breakdown cell divider

!a"Clean the output cable ,dispose the short !b"Check and repair !c"Check and repair

mixed into electrolyte

!d"Dire external surface of battery case .Metal impurities (d) Clean the battery case .Tighten shield .Replace elec trolyte if necessary

(2) Clutch Slip a. Thin friction lining, rivet reveal, or oil coat b. Weak pressure of diaphragm spring c. Too short free play of pedal d. Vehicle loads too much e. Not start in low gear f. The pedal is hold pressed when running

a. Clean, or rivet a new friction lining b. Replace c. Adjust to 3~5mm d. Load accord the rated load e. Start in low gear f. Change your bad driving habit

68

69

HFC1048
series trucks

3+Drive shaft trouble shooting

Trouble symptom and probable cause Checking and remedy Trouble symptom and probable cause Checking and remedy

(3) Clutch can't release completely a. Too long free play of pedal b. Wear or crack locking collar c. Crack or distort of wave sheet d. Broken damper spring

(1) Noise or vibration of driveshaft a. Adjust to 3~5mm b. Replace c. Replace d. Replace a. Worn universal joint b. Bending of drive shaft c. Loose couple flange or center bracket bolts d. Defective center bracket rubber sleeve e. Insufficient lubrication a. Change spider direction or replace universal joint as sembly b. Align or replace c. Retighten d. Replace e. Fill up after cleaning

(4) Gears hard to mesh a. High speed idle speed of engine b. Improper meshing of clutch c. Coherence of clutch plate d. Bend clutch slip sleeve a. Adjust the idle speed b. Adjust clutch c. Repair or replace d. Replace (2) Overheating center bracket a. Too much tight of oil seal crankshaft c. Insufficient lubrication 70 c. Fill up regularly 71 a. It will disappear along with travel longer b. Too bigger a inclination between drive shaft and b. Check and adjust the inclination

HFC1048
series trucks

4. Transmission trouble shooting

Trouble symptom and probable cause (1) Gears break off a. Worn or damaged coupling b. Loosen nuts or bolts c. Improperly adjusted linkage d. Distorted, worn, or crack spring or locking ball e. Worn shift fork and groove face f. Worn synchronizer hub and sleeve sleeve h. Worn or damaged bearing of input shaft and output h. Replace bearing shaft i. Worn or damaged thrust ring and thrust washer j. Loosen bolts which mount transmission to engine 72 i. Replace j. Tighten a. Replace the coupling b. Tighten c. Readjust d. Repair or replace parts e. Replace shift fork f. Replace (3) Noise from transmission a. Loosen bolts which mount transmission to engine b. Worn gear or bearing (4) Hard to shift a. Improper adjustment of shift knob b. Worn hinge joint or pin c. Worn control mechanism d. Loosen bolts or nuts a. Tighten b. Replace Checking and remedy Trouble symptom and probable cause (2) Gears hard to mesh a. High speed idle speed of engine b. Improper meshing of clutch c. Coherence of clutch plate d. Bend clutch slip sleeve Checking and remedy

a. Adjust the idle speed b. Adjust clutch c. Repair or replace d. Replace

g. Worn or damaged synchronizer hub and engagement g. Replace

a. Adjust shift knob b. Replace c. Replace d. Check and tighten 73

HFC1048
series trucks

56Front axle trouble shooting

Trouble symptom and probable cause (1) Hard steering, steering wheel doesn't return well a. Insufficient lubrication of steering linkage mechanism b. Improper alignment of front wheel c. Improper toe in of front wheel d. Improper camber and caster of king pin e. Worn thrust bearing f. Insufficient pressure of tire a. Apply lubrication on king pin and ball stud b. Adjust c. Adjust d. Check the linear for wear, and check knuckle and tie rod for deviation, replace if necessary e. Replace f. Inflate properly Checking and remedy Trouble symptom and probable cause !3"Vibrate oscillate Checking and remedy

a. Improper position fix of front wheel b. Worn king pin linear c. Improper pretightening of hub bearing d. Worn hub bearing e. Loosen ball stud of tie rod f. Loosen nuts on U-type bolt g. Loosen hub nuts h. Distorted wheel i. Unbalance wheel j. Wheel deviation k. Asymmetry or insufficient inflation of tire

a. Adjust, and replace if necessary b. Replace linear c. Adjust d. Replace e. Replace all end parts of tie rod f. Tighten g. Tighten h. Replace i. Adjust and balance j. Adjust k. Adjust, inflate !b"replace !c"adjust !d"replace 75

(2) Abnormal worn tire a. Improper position fix of front wheel b. Improper pressure of front tire a. Adjust, and replace if necessary b. Adjust, and inflate

!a"front wheel location is wrong !b"damage of the main bush !d"damage of wheel hub axle

!c"the tight of wheel hub is wrong

74

HFC1048
series trucks

6. Rear axle trouble shooting

Trouble symptom and probable cause !e"cross pull rod ball end is loosen !g"the nut of wheel hub are loosen !h"the distortion of wheel !j"the wap of wheel !i"the wheel are not imbalance !k"shortage of the air pressure Checking and remedy !e"change the parts !f"tighten !g"tighten !j"adjust !h"replace Trouble symptom and probable cause (1) Abnormal noise from rear axle a. Worn or damaged pinion bearing b. Worn or damaged side bearing of differential c. Loosen pinion bearing d. Loosen differential bearing e. Worn pinion and ring gear f. Worn thrust washer g. Worn differential spider h. Worn pinion and ring gear i. Worn or damaged side gear and planetary gear !4"leak grease from wheel hub !a"damage of oil seal !c"too much grease !b"hub cover is loosen j. Loosen tightening bolts of ring gear !a"replace !b"tighten !c"use grease to fix k. Improper contact between ring gear and pinion l. Worn pinion spline m. Worn rear half shaft spline n. Loosen hub bearing o. Worn hub bearing a. Replace bearing b. Replace bearing c. Adjust preload d. Adjust preload e. Adjust tooth space f. Replace g. Replace h. Replace i. Replace j. Tighten k. Replace or adjust l. Replace m. Replace n. Replace o. Adjust bearing preload 77 !f"U type of nut and blot are loosen Checking and remedy

!i"adjust the balance !k"adjust$charge air

76

HFC1048
series trucks

7. Steering mechanism trouble shooting

Trouble symptom and probable cause p. Loose tightening bolts of differential case q. Insufficient oil r. Bad oil p. Tighten q. Fill up r. Replace Checking and remedy Trouble symptom and probable cause (1) Hard to steer and steering wheel with bad return a. Distorted main shaft, sliding shaft or column b. Loosen universal joint or column cover c. Improper rotation of steering wheel bearing d. Insufficient lubrication of steering linkage mechanism e. Low pressure tire Checking and remedy

a. Replace parts b. Replace universal joint c. Replace parts d. Fill up lubrication e. Inflate properly

(2) half shaft seal Leaking a. Jammed rear axle vent hole a. Fill up and readjust b. Bad lubrication b. Replace lubrication accord the season c. Tight between pinion and driven gear, tight bearing, c. Readjust and tight over on bearing (3) Hot rear axle a. Oil leak because of damaged seal gasket, loosen oil a. Fill up and readjust drain plug, and jammed vent hole, result in insufficient lu brication b. Bad lubrication b. Replace lubrication accord the season c. Tight over between pinion and driven gear, tight over c. Readjust on bearing 78

(2) Shake of steering wheel, instable steering a. Loosen steering linkage mechanism b. Unbalance front wheel c. Pendulate too much d. Damaged grinding wheel a. Tighten properly b. Balance the wheel c. Adjust

d. Replace e. Heavy wear or too big clearance of steering linkage e. Replace parts mechanism 79

HFC1048
series trucks

8. Running brake trouble shooting

Trouble symptom and probable cause (3) Wander front wheel a. One of front brake or damper is disabled b. One of front tire low pressure c. Disalign or break of front leaf spring d. Damaged grinding wheel e. Improper toe in of front wheel (4) Power steering bump leaking a. Damaged oil seal or O ring b. Damaged oil seal locking nuts or oil-drain plug Checking and remedy Trouble symptom and probable cause (1)shortage of brake a. Adjust the brake clearance or replace damper b. Inflate tires c. Check front spring assembly d.Adjust or replace e. Readjust !a"adjust the brake room Checking and remedy !a"adjust the pull rod

!b"have some dirty things !e"brake valve lead air !g"brake drum

!c"brake cam and shoe brake are rustiness

!b"use buck to washing !e"change valve base !f"adjust !g"adjust and change !h"clean it

!d"brake room epithelia and pipe are leak air !f"the distance between brake and shoe plate is too large

!c"clean the rustiness and grease

!d"change epithelia ,check the air part

a. Replace b. Repair

!h"have dirty things on the pipe !2"brake moment is partial

!i"enter air to brake valve is slowly !a"brake shoe plate unseemliness !c"shoe plate have oil dirt !d"the wheel is empty. !e"brake drum is change

!i"check enter air of the karat !a"adjust !c"clean

(5) Heavy steering a. Bad steering gear b. Bad steering gear c. Improper preload sector gear bearing

a. Replace piston set b. Check pump for output pressure, replace if necessary c. Adjust the pretightening force of bearing

!b"one side of brake shoe plate is rustiness

!b"grease !d"ordain air press !e"adjust and grind 81

80

HFC1048
series trucks

9. Parking brake failure shooting

Trouble symptom and probable cause Checking and remedy

10. Suspension trouble shooting

Trouble symptom and probable cause Checking and remedy

a. Big clearance between brake pad and drum b. Oil coat on brake pad or drum c. Badly worn friction pad

a. Adjust the clearance until both its upper and lower is 0.65mm b. Clean with water c. Replace

(1) Broken leaf spring a. Load too much or partial to one wheel road c. Loosen U-bolt. Loosen or broken spring clamp d. Failed damper a. Load properly as rated brake and slower speed on uneven road c. Tighten U-bolt. Tighten or replace spring clamp. d. Repair or replace b. Frequent emergency brake, drive too fast on uneven b. Keep your mind on driving, so that avoid emergency

2) Noise in driving (3) Bad absorption a. Insufficient damping fluid b. Having no maintaince regularly c. Damaged rubber collar

Check and replace rubber suspension part

a. Fill up as rated b. Maintain regularly c. Replace

82

83

HFC1048
series trucks

11. Wheel trouble shooting

Trouble symptom and probable cause (1) Badly worn tire a. High or low tire pressure b. Too much overloading or dissymmetrical loading c. Loosen wheel hub bearing d. Improper toe-in of front wheel a. Inflate by specification b. Load as rated c. Adjust d. Adjust the toe-in until it is 3~6mm (for diagonal tire) and 1~3mm (for radial tire) e. Frequent emergency brake, flare up when starting, or e. Drive stably, don't drive too fast accelerate suddenly f. No wheel transposition f. Transposition regularly Checking and remedy

( Automotive model table of trucks

Engine No. Vehicle type Engine type power (ml/kW) 1 HFC1048K type truck HFC1048KR1 type truck HFC1048K1 type truck HFC1048K1R1 type truck HFC1048KD type truck YZ4102QF YZ4105QF CY4102BQ 3856/70.6 4087/75 3856/70.6 5910;2096;2250 3800;1960;400 3308 Outside dimension (l'w'h) (mm) 5910;2096;2250 Inside dimension of the cargo body (l'w'h) 7mm8 4130;1960;400 Axle Base (mm) 3308

CY4102BZLQ YZ4102ZLQ CY4102BZLQ YZ4102ZLQ CY4102BZLQ CY4102BZQ

3856/88 3432/81 3856/88 3432/81 3856/88 3856/88

5910;2096;2250

4130;1960;400

3308

5910;2090;2250

3800;1960;400

3308

5910;2096;2250

4130;1960;400

3308

84

85

HFC1048
series trucks

Engine No. Vehicle type Engine type power (ml/kW) HFC1048KR1D type truck HFC1048K8 type truck HFC1048K8R1 type truck HFC1048K9 type truck HFC1048K9R1 type truck CY4102BZLQ CY4102BZQ CY4102BZLQ YZ4102ZLQ CY4102BZLQ YZ4102ZLQ 3856/88 3856/88 3856/88 3432/81 3856/88 3432/81

Outside dimension (l'w'h) (mm)

Inside dimension of the cargo body (l'w'h) 7mm8 3800;1960;400

Axle Base (mm)

Umber of No. leaf springs (front/rear) tyre

Tread (front/rear) (mm) 1665/1525 1665/1485 1665/1525 1665/1485 1665/1525 1665/1485 1665/1525 1665/1485 1665/1525 1665/1485

Cross vehicle weight (kg)

Max load capacity (kg)

Curb wigh (kg)

Front/rear suspension (mm)

5910;2090;2250

3308

12/14

7.00-16

4480

1920

2560

23/14

1105/1497

5910;2096;2250

4130;1960;400

3308

12/14

7.00-16

4480

1920

2560

23/14

1105/1497

5910;2090;2250

3800;1960;400

3308

12/14

7.00-16

4480

1725

2560

23/14

1105/1497

HFC4DA1-1

2771/68

5910;2096;2250

4130;1960;400

3308

12/14

7.00-16

4480

1725

2560

23/14

1105/1497

10

HFC4DA1-1

2771/68

5910;2096;2250

3800;1960;400

3308

12/14

7.00-16 7.50-16

4480

1725

2560

23/14

1105/1497

86

87

HFC1048
series trucks

Umber of No. leaf springs (front/rear) 7.00-16 7.50-16 tyre

Tread (front/rear) (mm) 1665/1525 1665/1485 1665/1525 1665/1485 1665/1525 1665/1485 1665/1525 1665/1485 1665/1525 1665/1485

Cross vehicle weight (kg)

Max load capacity (kg)

Curb wigh (kg)

Front/rear suspension (mm)

) Appendix
Main lubricating position and the lubricant name(for reference) Description of the oil in lubricating table (for reference)

12/14

4480

1725

2560

23/14

1105/1497

Main files along with the vehicle

12/14

7.00-16

4480

1725

2560

23/14

1105/1497

12/14

7.00-16

4480

1725

2560

23/14

1105/1497

12/14

7.00-16

4365

1790

2380

1185/2050

10

12/14

7.00-16

4365

1785

2380

1185/2050

88

89

HFC1048
series trucks

Table one Main lubricating position and the lubricant name(for reference)
No. Lubricating position Symbol of Number of everyday maintenace cycle First time Seconde time Third time Every season No. Lubricating position the lubricant the ubricating G G G Z Y Z G 1 3 1 2 6L!reference" suitable 1 2 check fill fill fill replace replace replace replace replace

Symbol of

Number of everyday fill

maintenace cycle First time Seconde time Third time Every season

the lubricant the ubricating G D ZL Q G G Z 2 1 Each 2 2 1 1 1 1 ZL 2

9 10 11 12 13 14 15 16 17

generator Power steering bearing of the front rear hub Shack absorber Water pump bearing Transimission drive gear front bearing Rear axle Engine lubrication system Cooling system drive mechanism

1 2 3 4 5 6 7 8 90

universal joint of the driveshaft spline of the driveshaft battery terminal transmission oil cup of the clutch brake master cylinder steering gear steering knuckle pin and ball pin of the drag link and the tie rod Filer cartride

fill

replace

replace replace fill

fill

fill replace

one change one year fill fill replace replace replace

fill fill fill replace

replace replace

91

HFC1048
series trucks

Table two Description of the oil in lubricating table (for reference)

Symbol in the table B J G ZL Q Y Z D 92 Lubricant L-BCD4 oil GB11123!summer"$LECD30 oil GB11123!winter" 15W/20 or 15W/40 thickened oil GB49 2# lime base grease GB5671 universal lithium base grease Half HU-20 gasoline engine oil!GB2537"and half 45# transformer oil !GB2536" brake fluid JG3!GB10830" medium-load vehicle gear oil!GL-4" 85W/90 L-HM46(GB11119), the below zero is L-LM32(GB11119) antiwear hydraulic oil.

Table three Tightening torque of main fastening pieces (for reference)

Number 1 2 3 4 5 6 7 8 9 10 11 12 13 Nuts of steering tie rod ball pin Nuts connected the transmission and the clutch housing Intermediate driveshaft flange nuts tyer nut Diving gear flange nuts Fixing nuts of the steering straight arm U-bolt of the front leaf spring U-bolt of the rear leaf spring steering fix bolt Fixing nuts of steering flexural arm Steering-wheel fix nut Transmission flange nuts Pitman arm shaft nut Name Tightening torque7N < m8 186=20!19=2" 68.8-93.2!7-9.5" 343-539!35-55" 196-245!20-25" 441=49!45=5" 250 350 68.8-88.2!7-9" 441=49!45=5" 49-78.4!5-8" >166.7!17"

220-250!23-25.5"

196-235.2!20-24" 93

HFC1048
series trucks

Main files along with the vehicle

1 "Operating specification of HFC1040 series trucks# 2 "Operating specification of engine# 3 Products certification

The nameplate of JAC series trucks is located on the right side of longitudinal member beside front suspension.

ANHUI JIANGHUAI AUTOMOBILE CO., LTD. Address>176# Dongliu Road Hefei City Telephone>0551-2296374 Postalcode>230022 Network address>http://www.jac.com.cn

94

95