jac light truck hfc1040

Thanks for your using JAC trucks!Before your using JAC trucks, please read this operating specification carefully and operate the trucks according to thespecification to bring JAC trucks' excellent performance into full play and keep the trucks in a good running state in along time!JAC trucks are developed and produced jointly by Anhui Province Automobile Research Institute and Anhui JianghuaiAutomobile Co., LTD. As well as the road conditions are taken to fully condition, the domestic and overseas modern design and producing technique of body and chassis are absorbed and adopted to let JAC trucks bear good smoothnessand 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 anddata in the specification are based on the latest material when compiling. We would not inform you after making somemodification 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: 0551-2296374The service consultation telephone number: 0551-2296361Anhui Jianghuai Automobile Co.

ANHUI JIANGHUAI AUTOMOBILE CO., LTD.May. 2008

Preface

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 1Engine 21Chassis 29IVElectrical equipment 55Vehicle service and maintenance 61Trouble shooting 65Automotive model table of trucks 85Appendix 89Main files alone with the vehicle 94

Contents

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

(). Use of components in the cab

(). Start and running of vehicle

( ). Use of instrumentsand apparatuses in the cab1. Integrated switch and instrument clusterIntegrated switch (figure below)which is composed of steering shaftlock seatignition start lock andcombination switch lies underneaththe steering wheel.

1) Ignition switchIgnition switch is on the right side ofintegrated switch. It has four functions: LOCKACCONSTART. Whenthe key is on the 'LOCK' position,the ignition switch has been connected to the power source and thelockup of steering gear has beendisengaged. Turn the key to 'ACC'position clockwise, the circuit of accessories like radio and tape playercan be connected. Turn to the 'ON'position, and the instrument circuit isconnected. If keep on turning until tothe 'START' position, the engine canbe started. You should unlash thehandle of the key immediately afterthe engine started. And the key canreturn to the 'ON' position by the ac

tion of spring. The schematic diagram of ignition switch is as follows.

2) Combination switch ( left controlhandle)

left control handle

schematic diagram of ignition switchcombinationswitch

ignition switch

schematic diagram of integrated switch

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HFC1048series trucks

Combination switch is under thecontrol of the multifunction handle,which lies in the lower left and inferior place of the steering wheel. It cancontrol small lightheadlightheadlight dimmer and turning to the left orthe right by two different movementmodes. The symbol and function ofthe combination switch is as follows: The OFF symbol indicates thatsmall light and headlight do not light.(But at this time the high beam canlight if you put up the handle.) The symbol is the indication of small light. Turn the controlhandle clockwise by 30 ,and thefrontrear small lights and the instrument light can light. The symbol is the indica

tion of headlight. Keep on the turningof the left control handle clockwiseby 30 , the front headlightthe rearsmall light and the instrument lightcan light. The symbol is the indication of steering. Forward and backward motion of the control handlecan operate the left and right turninglamp and the turn light indicator inthe instrument panel. Push the control handle forward in the horizontaldirection, the right turning lamp lightsand there has the indication of turning right in the instrument panel. Onthe other hand, pull the control handle backward, the left turning lamplights and there has the indication ofturning left in the instrument panel. If

the control handle is in the middleposition, then there has no indicationof turning. Dimmer of headlight: Lift the leftcontrol handle upwards gently anddo the 'uplift -looseness' motion, itcan control the dimmer function ofthe headlight. Uplift the handle once,high beam headlamp lights; loosethe handle, it goes out. Repeatingthe above action can control thework status of the high beam headlamp to obtain the purpose of dimmer function when overtaking orpassing in night.

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43)Combination switch (right controlhandle)

The symbol is indication ofthe scrubber. When the washer control button on the top of the controlhandle pressed, the cleaning mixture(using antifreeze fluid in winter) in thewindow washer which lies in the rightdoorframe and underneath instrument panel can be spouted to thewindshield glass through the spoutunder the window. The symbol is indication of

the wiper. Turning the control handleclockwise in the horizontal directioncan control the wiper. Turn the control handle clockwise by 12 to the'LO' position, then the wiper workswith low speed. Keep the turningclockwise for another 12 , the wipercan work with high speed. When thecontrol handle is on the original position, it can be disconnected or returned automatically. The symbol is indication ofexhaust throttle assistant braking. Liftthe right control handle upwards anddo the 'uplift-looseness' motion. Uplift the handle, then the switch can beconnected and the indicator lamp inthe instrument panel lights. Thisshows that exhaust throttle assistant

braking works. If the acceleratorpedal or the clutch pedal wasstepped, the exhaust assistant braking should cancelled automaticallyand the indicator lamp in the instrument panel went out.4) Other electric appliance switch (seen in the left and below figure)Other electric appliance switchesmainly include horn button, dangerwarning switch, fog lamp switch,courtesy lamp switch and ceilinglight switch. The horn button is in the center ofsteering wheel, when the button isdepressed it can hoot. The symbol ( the right andbelow figure) is indication of dangerwarning switch. If the button is de

right control handle


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pressed, the front rear left rightturning lamp flash at the same timeand send out emergency signal foralarm indication. Press the button again, reset signal of the switch disconnected. The symbol ( the right andbelow figure) is indication of the foglamp. If pressed, the fog lamp lights.Press again, the switch resets. Ceiling light signal indicates thatthe door of the vehicle is shut closelyor not. When there have one dooropened or did not shut closely, theceiling lamp lights to remind driver.

5) instrument cluster

danger alarm and fog lamp switch

other electric appliance switch

instrument cluster(air brake)

instrument cluster(hydraulic brake)

7(). Use of components inthe cabCabBrief description of the structureThe driver cab is forward control cabwith full metal enclosed construction.Window glass adopts panoramiccamber windshield. In order to improve the comfort, side panel withlarger upside width and raised -roofcab have been adopted. Thereforethe interior space of the cab can bemore commodious and comfortable.Effective measures have taken in reduce noise heat insulation soundinsulation and sealing. For instances,the section of roof forehead is enclosed and strengthening rib is equipped on the roof. There have

three asbestos heat insulating mattress on the upside of the engine.Sealing of the door is double skinconstruction. At the aspect of safety,softening has done to the main parts,which can appear knocking easilywith passengers.

The air condition system(chooseto pack)1.Brief introductionThe automobile air -conditioner andthe automobile instrument panel is anintegral body which have cold airand warm air machine. It has manyuseful functions , or example ,tomaking cold air ,warm air and to removing frost . The air -conditionersystem has four high and low steps ,

so the customer can choose whatyou like ,for example , can choosethe same way to sending wind.

2.Operation2.1 To operating the engine2.2 To press the switch for the air -conditioner , then operating the airvolume .The switch has four grades ,from left to right ,so the air volume ofair -conditioner will be more andmore strong.

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Indicators (figure in the above page): Turn indicator lamp( ) whenthe turning control handle is on theleft (right) turning position, left (right)turning indicator lamp flashes. If thewarning switch is pressed, the leftand right turning indicator lampsflash at the same time. High beam indicator lamp( )indicates that the headlamp is in the

status of high beam or not. When theheadlamp is on the high beam status, the indicator lamp lights. Fuel warning lamp( ): fuel levelalarm, when fuel is in shortage, fuelalarm lamp lights. Parking brake indicator lamp when pull up the parking brakehandle,the indicator lamp lights. Exhaust assistant brake indicatorlamp when exhaust assistantbraking operates, the indicator lamplights. When exhaust assistant brakeis disconnected, the indicator lampgoes out. Oil pressure indicator lamp indicates low - pressure warning ofengine oil pressure. When oil pressure is lower than 0.08-0.1Mpa , the

oil pressure indicator lamp lights.When oil pressure is higher than thevalue, the oil pressure indicator lampgoes out. Braking fault indicator lamp when braking fluid is not enough, theindicator lamp lights. Exhaust assistant brake indicatorlamp when exhaust assistantbraking operates,the indicator lamplights. When exhaust assistant brakeis disconnected,the indicator lampgoes out. Fog lamp indicator lamp when braking fluid is not enough, theindicator lamp lights. Small light indicator lamp When they workhe indicator lamplights.

1turn left 2high beam 3turn right4fuel alarm 5parking brake6charging 7oil pressure alarm8braking fault 9exhaust assistantbrake 10fog lamp 11small light

indicators


82.3 To operating air -conditionerswitches 5,then the compressor begins to work at this time .The wholesystem will be colder.2.4 Using the cold wind , please putthe temperature adjusting handle 3 tothe COOL position .Using the warmwind ,you should put in the HOT position .To changing the wind-position,choose the handle 2 can make thecold (warm) breeze never lead withdirection .If you want to using thewarm wind ,you should be closeswitch of the air condition.2.5 To turning the natural wind conversion , then pressing the handle1can make the natural wind fromoutside of the car.

3.Caution3.1 You should be avoid the handlein the most cold position when usingt he air-conditioner in order to prevent evaporate the machine fromfrost.3.2 Do not park the cars under thesun .3.3 To using air -conditioners, youshould be close windows and doorsof the cab.3.4 To cleaning the condenser , youshould be wash with the compressedair or cold water ,do not wash itstrictly with the hot water or steam.3.5 The air-conditioner does not usein winter , however ,you should berevolve compressor once a weekabout five minutes .In order to main

tain the air -conditioner for normalworked.3.6 If you want to use the air heater ,the temperature degree of engineshould reach to 70 s above .At 0s the automobile should not park inthe cool environment, it should beuse antifreeze fluid, in order to preventing frost radiator and air heater.3.7 If you do not know the preventions about the air -conditioner , donot switch it , the in order to preventresults in trouble.The top of cab's ventilating devicewhich has two ways for it .One is exterior air with indoor ,another one ishouse airiness .

i. Leading exterior air(1) Clockwise the rotary-knob on the


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

ii. Indoor airiness(1) Clockwise the rotary knob to closing the ventilator louver.(2) Turn to the switch to "out "which isthe exhaust gear position.

Door1) The cab door, which have three-

step opening, can improve the convenience for passengers getting onor off. The opening angle of the doorcan be 30o 57o and 90o. The former two angles are partially openand the last angle is full open. On allthe three positions, the door can bein stable condition. outside door handle

lock button

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2) Outside door handlePull out the outside door handle, andthen the door can be opened. Insertthe starting switch key into the doorlock and turn, the door can belocked.3) The door can be locked outsidewithout the key. First press down thelock button (figure in the abovepage) at the inner side of the door tothe fixed position, then pull the outside door handle outwards and atthe same time close the door.4) Pull out the inside door handle,and the door can be opened. Afterclosing the door, the door can belocked if the lock button is presseddown.

Cab seatCab seat can be classified as driverseat assistant driver seat and rearrow seat. Driver back seat adopts upright seat. The angle of backrest andthe fore-and-aft position of seat canbe adjusted. The maximum adjustable angle of the backrest is 56o.The maximum adjustable distance ofthe seat is 160 mm. The seat adjustsystem is shown in the right figure.When vehicle is in the progress ofmaintenance, please clean the trackassembly of the driver seat, recoat thelithium base grease, and tighten alljoint nuts again. If found that the cabtrack slide seat has shaking or blockbecause of distortion, it should be repaired or replaced with components.


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Cab tilt lock mechanism

Brief of the structureThe cab has turnover functions , alsohas turnover and lock up organization . The turnover was composed oftorsion bar, supporting -axle,

cab'srear bracket and so on.The cabto turnover is used by torsion power.Lock up system is composed ofright/left lock unit ,turnover lock unit ,short pull rod ,long pull rod ,rearbracket of cab and so on .All of thisis to lock the cab too tightly.(as picture)Please read the tilting notes on theleft door of the cab and on the upperflange of the wheel seriously beforetilting the cab. The notes are shownin the upper figureUse and maintenanceIn order to tilting the cab reliably andrunning the vehicle safely, pleasepay attention to following contents.1Cab tilting method and relativeattentive notices.

When the vehicle is stopped onthe horizontal road, you should makesure that there has enough spacearound the cab before tilting. Or else,the cab may be damaged while tilting.

1.chuck rod2.overturn rod3.safe locking hook

notice

schematic diagram ofcab tilt locking device

support rod assembly

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Pull up the parking brake; pushthe shifting lever into the neutral position to avoid the self -sliding of thevehicle. The cab door must be fastenedup. You should take all goods on theinstrument panel seat and flooraway to avoid the damage of thedoor and the front windshield. First disengaged the lockingfunction of the cab locking mechanism when tilting the cab. After the locking function disengaged, hold the tilting rod with handand pull up the safety lock hook atthe same time to avoid the suddenuplift of the cab. Raise the cab slowly until it is tilted to the maximum position, then

lock it reliably with lock arm on therear bracket. It is shown in the rightfigure. When lowering the cab down, firsthold the tilting rod and disengagethe locking function of lock arm onthe rear bracket, then lower the cabdown slowly. After the safety locklocked, fasten the locking mechanism.2Inspection and maintenance Check periodically the rubber padassemblies which are used tostrengthen the frontrear support, iffind damaged, it should be replacedinstantly. Check periodically the locking situation of the locking mechanism, ifinvalidation of locking function found,

it should be repaired or replaced immediately. If felt arduous when tilting up thecab or heavy when dropping downthe cab, the torsion rod is invalid. Replace the torsion rod. When repairing the chassis, before removing of the cab, disengagethe force of the torsion rod and operate with following steps.a. Disengage the locking state, andtilt up the cab to the utmost position.b. Remove the shaft pin connectedthe rear support rod and the baseboard support of the cab.c. Push the cab forwards for someangle until the bolt on the torsion rodarm can be loosened.d. After the bolt removed, the torsion


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rod cannot work. Now the cab canbe removed ( The torsion rod can notbe pulled out).Note: The above -mentioned workmust be done by three persons atleast because two or three personscannot push the cab forward afterthe force of the torsion rod is disengaged. Before reverting the cab to the original position, return the force of thetorsion rod and operate with following steps:a. Put the tooth part of the splinewhich is cut at the bottom on oneend of the torsion rod in alignmentwith '1' position on the support axletube and the spline tube, and insertthe torsion rod into the support axle

tube ( for the rod which is pulledout).b. After mount the cab with supportaxle tube and the left right brackettogether to the frame, put the '1' ofhub splines on the torsion rod inalignment with the spline tooth whichis cut at the bottom on the other endof the torsion rod, cover the hubsplines on the torsion rod and insertthe spline axle tube into the rightbracket in the cab.c. Tilt the cab forwards until the bolthole on the torsion rod arm aimed atthe screwed hole on the right bracketin the cab, screw the bolt and tightenit.d. Put the cab down slowly, andcheck whether the cab is on the

state of suspending at the horizontaldirection after dropped down. If normally, then lock the cab. If find invalidation of the torsionrod, when replacing, operates according to .

(). Starting and running ofthe vehicle1. Starting of the vehicle1Starting of the engineWhen starting the engine, put theshift bar on the neutral position, turnon the ignition switch, check hornsinstruments on the instrument panelturning lamps braking lamps theangle and position of the rear viewmirror. Routine start

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Turn the key to the START position(shown in the right figure), the enginecan start. After starting, loosen theaccelerator pedal immediately andkeep the engine working in lowspeed. Depressing the acceleratorpedal violently is forbidden. Start in winterWhen the weather is very cold, thestart of diesel engine can take following measures:a. Cooling water use hot water, andunclose the drain switch whenadding hot water. When the hot waterflowed out and the engine body became warmer, close the drain switch.

b. Heat up the oil up to 8090 ,and then add it into the oil pan.After starting the engine, check theoperating state of the engine and instruments at different rotating speed.Especially check the oil pressure.Check if there have leakage of water oil and gas, check whether the

oil level is normal and the enginehave abnormal noise. Check whetherthe color of exhaust is normal. After starting the engine, do notdepress the accelerator pedal violently, loosen the accelerator pedal tokeep the engine operating on idle forsome time. After the temperature ofengine rises and the engine operatesstably, uplift the clutch pedal slowly. Generally after the temperature ofengine become more than 60 andthe operating (sound) of the enginecomponentsthe reading of instruments are normal, the vehicle canrun. Do not run the vehicle in lowtemperature to avoid intense wear ofthe engine.2Starting and shifting of the vehicle

starting switch


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After engine operates normally, depress the clutch pedal, shift into lowgear, loosen the parking brake, andpress the horn once. Making surethat the vehicle can be operatedsafely, loosen the clutch pedal slowlyand depress the accelerator pedalproperly at the same time to start thevehicle. After starting the vehicle, thefoot should get away from the clutchpedal. Do not keep the foot on thepedal to avoid the burning out of theclutch friction disc.Note: Do not let the vehicle runningin first or second gear for long timeto prevent from increasing the wearand the fuel consumption. Loosenthe clutch pedal rapidly or depressthe accelerator pedal insufficiently,

the engine can stop.When running the vehicle, shift thegear according to the change ofroad and landform. If find that theengine power is in abundance andthe rotating speed rises, it illustratesthat the primary gear is not appropriate, the vehicle should be shifted tothe next fast gear in time. After shifting, if not finding shortage of powerand chattering of transmission, theshifting operation can be consideredright. If find shortage of power or thevehicle speed decreases, the vehicleshould be shifted to a low gear. If thevehicle runs normally after shifting,the shifting into low gear is right.for safety, when swervepassingbridge and meeting, the vehicle can

run in moderate speed. On betterrunning condition, the vehicle can operate in fast gear, and at this time thevehicle speed is high, the fuel consumption is low, the economy of fuelis good.When shifting, do not just see theshifting lever. You should watch forwards, hold the steering wheelsteadily with your left hand, let thecenter of the palm of your right handstuck to the top part of the shiftinglever and push or pull it to the needed position with the force of yourright wrist.

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2.Running swerve turnaro -und backing and braking ofthe vehicle1) RunningKeep enough distance to the foregoing vehicle when running on flatroad. Select vehicle speed accordingto the vehicle modelmission andconcrete condition of road, generallyselect the speed of 5070 km/h.Let the vehicle running in the first orsecond gear when starting, upgrading under heavy load and running onbumpy road or on the road havingobstacles. But the vehicle can notrunning in the first or second geartoo long in normally running. Whenupgrading with heavy load, shift theshifting lever into low gear to avoid

overloading of the engine.When running, do not increase or decrease the vehicle speed abruptlyand not shake the steering wheelwithout reason, listen whether there isabnormal noise or not, check thereading and indicator lamp of all instruments for normalization. If findabnormal noise or abnormal events,stop the vehicle immediately andcheck it, take necessary adjustmentand repair.When downgrading, do not stall theengine. When downgrading steepramp, shift the shifting lever into lowgear and take braking operation atintervals to avoid the over fast of thevehicle speed.When running across shallow river or

loblolly, prevent the water from entering into air intake lines of the enginerear axles and transmission case.Check rear axles and transmissioncase for entering water after paddling. If find water, drain it and addgear oil with specified quantity. Afterpaddling, the vehicle can not run inhigh speed. You should depress thebraking pedal every now and then toresume the braking performance assoon as possible.When running on the ice or snowroad, run with steady speed. Do nottake emergency braking and not turnthe steering wheel fiercely to avoidskidding danger. Keep long safetydistance from the foregoing vehicle.When running in heavy rain, drive the


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vehicle more carefully to avoid decreasing the braking performance ofthe brake because of moist. Do nottake emergency braking operation toavoid the danger of skidding.2) SwerveSwerve of the vehicle produces centrifugal force which can be biggerwhen the vehicle speed becomeshigher. The force can bring turningover in the transverse direction inserious condition. Therefore, at the50100 meters position before turning the vehicle, you should ring thehorn turn on the turning lamp andreduce the vehicle speed. Whenrunning on the freezing and muddyroad or in the weather of heavy rainfog wind sand, reduce the vehicle

speed to less than 10 km/h, swervethe vehicle slowly alongside the rightside of the road. When swerving, turnthe steering wheel uniformly according to the situation of road, theswerving track should be transitedsmoothly, the turning motion shouldnot be too great or too small. Do notturn or return the steering wheelsuddenly. Try your best to avoid taking braking operation while turningthe steering wheel, especially emergency braking.When steering, if found skidding offront wheels, put up the acceleratorpedal and turn the steering wheel inthe contrary direction; if found skidding of rear wheels, turn the steeringwheel properly along the skidding

direction, and after the skiddingstops, correct the running direction.3) Turning aroundWhen turning around for 180, selectthe squarelarge -scale crossing orflat broad road which have little traffic flux and turn around the vehicle ata time along the running direction. Atthe 50100 meters position in front ofthe turning spot, reduce the vehiclespeed, shift into low gear and sendout the turning around signal.When turning around with runningforwards and backwards, first sendout the turning around signal, reducethe vehicle speed and run towardsthe right side of road. When approaching the preset spot for turningaround, observe the situation of road,

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turn the steering wheel to the left extreme position rapidly and let the vehicle running to the left side of roadslowly. When approaching the roadside, return the steering wheelrapidly. After observing the situationbehind the vehicle, start and turnaround the vehicle, turn the steeringwheel to the right extreme position atthe same time. When approachingthe roadside, return the steeringwheel rapidly and stop the vehicle. Ifthe turning around operation can notbe done once time, repeat the aboveoperations.4) BackingThe operation of shifting into reversegear or shifting from reverse gear toonward gear can be done after the

vehicle is stopped completely. Aftershifting into the reverse gear, theback -up lamp lights. The vehiclespeed must be less than 5 km/hwhen backing. If the driver can notdiscern the situation behind the vehicle because the vehicle is loadingor other reasons, the backing operation must be commanded by oneperson who is outside the vehicle.Do not back the vehicle blindly.5) Parking of the vehicle and stop ofthe engineWhen preparing to park the vehicle,the vehicle speed reduces or the vehicle slides out of gear and indicateswith turning lamp. After the vehicleparked, pull up the parking brakelever. If the vehicle must be parked

on the road for some reason, parkthe vehicle near the roadside and notpark the vehicle on the running lane.Under the exceptional condition likebreaking down in the middle of road,two caution plates should be placedon the position of 200 meters in frontof and behind of the vehicle.Avoid parking on the ramp. If thevehicle must be parked on the ramp,pull up the parking brake lever to theextreme position, shift into low gearand block the vehicle with triangularchocks or stones to prevent it fromsliding. Note: Make sure that theparking brake can work reliably whenparking on the ramp, at the sametime turn on the emergency warningsignal indicator lamp.


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After parking, especially after the engine operates with heavy load, donot stall the engine immediately, butkeep the engine operating in lowspeed for several minutes. After thetemperature of water decreases lessthan 70, then stop the engine.When parking midway in winter, takethe heat preservation and antifreezing measures for the engine. Preventthe oil tank from insolation in summer.After the vehicle runs a day, routineservice and inspection should bedone on the entire vehicle.

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.Engine(). Inlet air exhaust systems(). Cooling system

(). Accelerating transmission system

(). Fuel supply system

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NoticeThe details of the engine structure assembling adjustment using and maintenance can be consulted in the operating specification of relevant engines.The position of the engine cardCauseThe card of engine is on the top cylinder head or on the side of engine .It writes the model number of engine ,sequence number ,declared power ,declared speed and the factory date .Pay attention to find it in order to using itclearly and convenience.(as picture)


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(). Inlet air exhaust systems1. Brief description of the structureInlet system includes air inlet pipeassembly air filter assembly intakemanifold. Exhaust system includesexhaust pipe muffler and exhausttailpipeUse and maintance1) The service life of the engine hasgreat relationship to the workmanshipof the air filter. Absolutely forbid thatthe engine works without air filter oron the condition that the air filter isdisabled. Taking the intake openingof air filter as the original intake opening is forbidden.

2) For every 1000km running, checkthe inlet and exhaust manifold for thefollowing:a. Check nuts for looseness, whentightening the nut on the inlet andexhaust manifold, the torsion forceshould be equable, or else the airleakage can occur.b. Check the inlet and exhaust manifold for crack and hole, check thegasket for damage and erosion, iffound, replace it with a new one.

Air filterThe function of air filter is to filter outthe dust and the sand in the air entered into the engine.Air filter is cyclone dust gathering aircleaner with paper filter element. After external air enters into the air filter

through the air inlet pipe, larger dustparticle can be separated from theair by the function of cyclone vane,then can be thrown into the dustgathering plate, the separated airkeep on moving and enter into thecylinder by the filtering function ofthe paper element.For every 1000km running, checkand maintain the air filter. When running in the condition of excessivedust, the running mileage interval forinspection and maintenance shouldbe shortened suitably.Cleaning of the air filter:1) Remove the dish-shaped nut fromthe end cover. Take away the endcover, remove the inner nut and takeoff the filter element assembly.

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2) Clean the cover cap and the innerpart of the housing with dry andclean cloth.When cleaning, do not letthe moisture enter into the air filter.

3) To cleaning dust unloading valvein order to usage well .4) Tight and close the rubber ofconnected brake .5) Clean the air filter element: clearaway the dry dirt or dust with compressed air gun (air pressure shouldbe less than 690kpa),blow from theinner side of filter element towardsoutside. Do not clear away the dirt orthe dust with beating or knocking.

(). Cooling system1.Brief description of the structureCooling system is closed water cooling pressure cycle type. It is composed of radiatorcoolingfiuidthermostat fan bulge radiator and water inlet and outlet pipes of radiator.

The concrete structure and type ofthe cooling system components canbe consulted in detail in the operating specification of relevant engines.

2.Using and maintenance of co-oling system1) Recommend using long effectiveantifreeze preservative liquid for cooling fluid. In the north, it can avoid thedamage of engine because of thefreezing of cooling fluid in winter; inthe south, it can increase the boilingpoint of cooling fluid in summer toavoid the damage of engine overheating because of air resistance inhigh temperature.2) Before dispatch the vehicle everytime, check the liquid level in the radiator and in the bulge radiator, if

1cab 2vent hose (1) of the air filter3intermediate connecting pipe4connection board5vent hose of the air filter6right longitudinal member of the frame7air filter bracket8intake pipeline of the air filter9connecting hose 10air filter

schematic diagram of air filter


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found it is not enough, add liquid tothe specified height.3) Drainage of cooling system. Incold region and in winter, without using antifreeze preservative liquid, iflong time parking or receiving thevehicle everyday, the cooling systemmust be drained. And you shouldopen the water filler cap of the radiator to avoid the incomplete drainageof cooling water.4) After engine operating for longtime, furring can produce in thecooling water and it should becleaned in time. Clean it with following method: mix 700 800 gramcaustic soda and 150 gramkerosene, add the mixture liquid intothe cooling water, run in medium

speed for 5 10 minutes, then afterstopping for 1012 hours, restart theengine and run for 10 15 minutes.Then drain the aqueous solution andclean the cooling system withcleaned water.

3.Advertent proceedings in usinglong effective antifreeze preservative liquid1) Choose suitable antifreeze liquidaccording to the minimum temperature of the region, if the minimumtemperature of the region is -25 ,antifreeze liquid whose solidifyingpoint is -30 should be chosen.2) When compensating antifreezepreservative liquid, choose the samemodel to avoid deposition.3) If find deterioration of antifreeze

preservative liquid, replace it entirelyat once. The color of antifreeze liquidis green or blue, if having deteriorated, the color should be dull red because of impurity infiltration.

To adjusting the degree of tension of the fan belt1.The disadvantage of engine istighten or lax the fan belt .Before useit please read the operating specification .2.The way of adjustment :firstly toadjusting blots ,secondly to adjusting,third to adjusting the tight ofwedge -shaped belt .Using fingerpress way ,to pressing for 98/N .Thestandard of crankshaft pulley is 2531mm .The standard of fan belt is78mm.

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() Accelerating transmission system1.Brief description of the structure

Accelerating transmission equipmentis composed of accelerator pedalmechanism accelerator wire drawing and acceleration governor arm ofthe engine. It is shown in the figure inthe above page.When depress the pedal, drivingmedium of the mechanism pull thewire drawing, control the openingextent of the accelerator to increaseor decrease the speed1 Accelerator pedal mechanism:Accelerator mechanism take thenewest structure of ISUZU truck. Itoperates simply and reliably and hasaccelerating wire drawing and handthrottle wire drawing; the pedal is thestructure with injected molding and ithas the trait of convenient assem

bling and little operating noise.2Accelerating wire drawing:It operates by the soft wire drawing.And it has traits of reliable structureconvenient layout little frictional resistance and stable transmission.3Hand throttle wire drawing:Using with the foot throttle can quicken the preheating of the engine or increase the idling speed.

2.Using and adjustment1) Check the chucking position of thelinkage rod and the acceleratormechanism for rightness and reliability, check the direction of the wiredrawing for straight and check onthe cornering for smooth transition.2) The pedal should be depressedeasily and to the extreme position

1stalling wire drawing 2assemblyof accelerator mechanism and pedal3front floor of the cab4acceleration wire drawing5stalling oscillating arm of the engine6acceleration oscillating arm of theengine 7frame

schematic diagram of acceleratingtransmission equipment


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without jamming. When releasing thepedal, it should be returned freely.3) When depressing the pedal, if thefree play is too big or the openingextent of the accelerator is not enough, adjust the position of bolts.

Fuel supply system1.Brief description of the structureFuel supply system is composed offuel tank fuel filter fuel pumpfuelinlet line and fuel return line.The function of the fuel supply system is to inject the specified quantitydiesel fuel of specified pressure andgood atomization into the cylinder atthe correct time with definite intervalof injection according to the operating requirement, and take good com

pression ignition with the air rapidly.Its operating state has important influence to the power and economyperformance of the engine.1) Coarse cleanerthe car's fuel piping have a DX150T spin-on oil filterflow volume is 1.5L/min. It can transition impurity and can separate waterand oil

2) Fuel tank:. The tank install the filtergauze inside the fuel filler port to prevent impurity of large particle entering into the fuel tank, set oil drainplug on the bottommost position ofthe fuel tank to drain the deposit andwater on the bottom of tank whencleaning the fuel tank.

Using and maintenance of coar-se cleaner1To tight all the pipe line .2When the DX150Tprecipitator wor-ks for 1000/km and 200hours, to waterproofing.

diesel precipitator

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ChassisClutch

Transmission

Drive shaft

Rear axle

Frame

Suspension set

Front axle

Steering system

Brake system

Wheel & Spare wheel riser

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lowed, or else, it can result in thedisability of the pedal deficiency ofthe effective travel and incompleterelease of the clutch etc. So theclutch can not work normally. Thework of air bleeding should be completed by two persons in the best,one person depress the clutch pedalin the cab, the other bleed the air inthe wheel cylinder. The schematicdiagram of air bleeding for the clutchwheel cylinder is shown .Take off the rubber cap of the airbleed screw on the wheel cylinder,link a plastic pipe on the air bleedscrew, put the other end of the pipeinto the container filled with brakefluid, depress the clutch pedal several times, fill the master cylinder and

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

Maintenance and adjustmentLong time use or incorrect adjustment and incomplete air bleeding ofthe clutch can bring the halfway release of the clutch, let the clutch onthe half contact state for long time,aggravate the wear of the clutchpressure plate and friction linings.The decrepitation burnt and exfoliation of the friction lining, and theburnout of the release bearing alsocan result in the abnormal operationof the clutch. When maintenance, allkinds of clearance of the clutch mustbe adjusted. When doing the thirdmaintenance for the trucks ,you mustclean general/dispant cylinder andliquid reservoir tank ,then fill greaseto hole of disengaging shaft.

1release fork 2dust cover3copper washer 4wheel cylinder5wrench 6soft plastic pipe7container 8braking

Clutch1.Brief description of the structureThe clutch equipped for this seriestruck is single -plate dry type diaphragm spring clutch, outside diameter of the driven plate is 254.The hydraulic control unit of theclutch is composed of the clutchpedaloil storage cup release cylinder (master cylinder) wheel cylinderand oil pipe. It is shown in the belowfigure.Adjustment of the clutch operating system1Adjust the limit screw of the clutchpedal (below figure) to make surethat the free play of the pedal is 35mm.

2Adjust the mas ter cylinder of theclutch: loosen the locknut on thepush rod of the master cylinder, rotate the end of the push rod to contact gently the with piston of themaster cylinder, then rotate the pushrod for 3/4 circle in the contrary direction, tighten the locknut of thepush rod, now the clearance between the push rod and the piston isabout 0.51mm.3Adjust wheel cylinder of the clutchTake off the return spring of the release fork, push the wheel cylinderpiston to the bottom of the cylinder,loosen the locknut on the push rod,push the release fork towards thebackside of the engine to the position where the release bearing andthe release fork contact barely, turn

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

4Bleed air from wheel cylinder ofthe clutchHaving air or oil leakage in the hydraulic pipeline of the clutch is unal

clutch pedal

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Transmission1.Brief description of the structureThe transmission equipped for thechassis of this series truck is manualdiscontinuously variable transmissionwith fixed shaft gear, and it has fivedriving gear and one reverse gear.The synchronizer has been equippedon the second third fourth and fifthgear. And the synchronizer is synchromesh gear system. The synchronizer for the first gear and the reversegear is holding mesh gear. Using ofthe synchronizer on the transmissioncan make the shifting operation conveniently, decrease the wear andshock on the gear end, extend theservice life of the gear tooth, shorten

the shifting time, increase the average vehicle speed and reduce theworking intensity of the driver. Thegear shifting operation is accomplished with the shifting control device of the transmission, which isshown in the figure on the next page.

2.Shifting control device of thetransmissionThe shifting control device of thetransmission is long distance soft cable type with high floor and short lever,and it take two flexible shaft to implement the gear selecting and shiftingwhich is shown in the figure on thenext page. It is composed of operating lever seatflexible shaft for gearselecting or shifting and the bracket.The core shaft of the interior flexible

shaft is steel cable, the operation ofgear selecting or shifting is completedby the pushing or pulling motion of thesteel cable. The ball on the flexibleshaft and adjusting screw are used foradjusting the total length of the flexibleshaft to ensure that the gear selectingor shifting can be to the correct position. There have symbols of each gearon the control handle of the transmission, it is shown in the below figure.

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control handle of transmission


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3.Using and maintenance1) If found the gear shifting can notoperate or operates difficultly whenthe engine is not working, it showsthat the gear shifting lever (or theflexible shaft) have bad adjustmentor the bolt becomes loose, now youmust adjust the control lever (or theflexible shaft), check and tighten every bolt and every nut.2) If found out-of-gear when runningon the rough road, the control lever(or the flexible shaft) have bad adjustment, and it should be adjustedcorrectly.3) If found free play of the controllever too large, check and tightenevery bolt and every nut.4) Do not take gear shifting operation

when the engine work at over fastspeed to avoid accelerating the wearof the synchronizer.5) When shifting, the force should begentle. The hand force must be acted on the control lever until the gearreaches the correct position. Shiftingwith flap of one push and one loosenis inappropriate and the shifting operation can not be accomplishedeasily in this way.6) Only after the vehicle stop andkeep steady, the shifting from drivinggear to reverse gear or from reversegear to driving gear can be done, orelse, the gear can be damaged.7) As the fifth gear is over -speedgear, in order to avoid the damageof the overspeed gear spoke , its

1 gear shift control lever2dust cover 3handle4floor of the cab5flexible shaft for gear selecting6transmission rocker arm for gearselecting7side bracket for gear selecting8flexible shaft for gear shifting9fixed bracket of the gear shiftingflexible shaft10rear cover of the clutch11transmission rocker arm for gearshiftingschematic diagram of the transmission

gear shift control device

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running speed is under 50 km/h, thefifth gear can be used .8) When running, if find there is abnormal noise in the transmission,stop the vehicle and check it, eliminate the malfunction.9) When sliding on the downgrade,stalling of the engine is unallowed,starting the engine with the inertia ofsliding on the downgrade is forbidden to avoid the damage of the gearand the synchronizer.10) In the running -in period of thenew vehicle, because the metalchipping which was produced by thefrictional function between new partsis bad to components in the transmission, especially to the life of theconical ring on the synchronizer, so

the lubricating oil should be replacedafter the running -in period of thenew vehicle expires. Under generalcondition, 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 transmission into the reverse gear, addthe kerosene, rotate the transmissionfor 23 minutes, then drain the kero-sene, add the pure gear oil.11 Check the oil level in the transmission frequently, if found the levelis under the lower edge surface ofthe oil filler bolt hole, sufficient oilshould be added.12 Check the outside bolt of thetransmission and the flange of the

second shaft for tightness and theoperating state of the component inthe transmission frequently, becausethe vent plug is blocked by dust andpressure in the transmission increases, the oil seepage or leakage maybe found, so the vent plug should becleaned periodically.13 The movement parts of shiftingoperation should be kept good lubricating, or else, the shifting operationmay become difficult because of thewear of the movement parts. If foundthe position of gear selecting is incorrect, or gear shifting become difficult or the transmission is out ofgear automatically in using, firstlyyou should readjust the gear selecting and gear shifting mechanism.


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() Drive shaft1.General structureThe two-piece driveshaft, connectedwith transmission on the front endand with rear axle on the back end.

2.Use & Inspection1Driveshaft has been counterpoisedin factory, it should be ensured not tobe impacted in use and not to beknocked and stacked in disassembleand carry. Replace if the shaft is distorted or the balancer is desquamated, otherwise there will be vibration,noise, and extra impact in travel, itcan damage power train and endanger driver.2Regularly check the cross shaftneedle bearing, check the sealing of

the slide spline and replace the oilseal when necessary3The first maintenance ,to fill greaseto universal joint ,slide spline ,oil pistol ,driving spindle and quickly tightthe blot in order to sliding the universal joint .According to moment ratioto checking and tighten driving spindle and the middle parts of bearingblots.The second maintenance ,to checking is there anything fall down aboutthe dirt proof boot ; is there anyproblems about move the universaljoint .when cross shaft in the middleof the needle bearing .The distancewould not be very large .If it is toolarge ,you would be disassemble theuniversal joint and you can depend

on what you need to changing needle bearing universal joint.When you do the third maintenance ,should be disassemble the drivingspindle .Pay attention to sign onflange ,cross shaft ,link fork, slidespline in order to mounting .Whenyou finished all the maintenances ,please do the blance check , thestandard of dyramic blance is 2750r/min.The amount of unbalance ismore than 144g.cmIV Rear axleThe brief of structure Single reduction rear axle ,as the final part ofpower train of truck ,is the drivingaxle ,and it is composed of finaldrive and differential and axle housing .Final drive can not only change

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the direction of driving force ,but alsoreduce the rotate speed .It is composed of drive pinion and drivengear and final drive .The drive pinionis composed with drive shaft ,whoseend with spline is connected with universal joint assembly by couplingflange .Center support is mounted intwo opposite conical bearing ,so thatit can suffer not only radical bearing ,but also axial force. Drive pinion,whose small-end journal mounted indirect tapered roller bearing, can only support radial force. It is fixed onthe flange which located on top leftof differential case by several bolts.A differential, composed of differential case and cross and four side pinions, let the left wheel rotate at a dif

ferent speed from the right wheel.Rear one -piece banjo style axlehousing is made by means of welding punched armor plate.Meshing of tooth face and clearanceadjustment of final drive(1) Check drive pinion bearing forpretension .The pretightening force ofdrive pinion bearing should be adjusted. Measuring in the bolt hole ofdrive pinion bearing case, the tangential pull should be 15~30N.(2)The pretightening force of drivepinion bearing can be adjusted bymeans of adding and reducing adjusting shim. Add shim can decreasefriction torque, while reducing shimcan increase it. There are three kindof shim according to thickness

(0.40mm, 0.45mm, 0.5mm).(3) Check final drive for meshing between drive pinion and driven gear.The contact area and side play between drive pinion and driven gearcan be adjusted by means of adjusting shim and adjusting collar of differential bearing. There are threekind of shim is 0.30mm and 0.4mm0.45mm, and the 0.5mm Normally,the clearance between these twogears is 0.15~0.25mm, while the sideplay ranges under 0.07mm. To adjustside play, measure four points withequal angle around the driven gear,and the gauge outfit of micrometershould be in a vertical position. Toadjust tooth contact area, driven gearshould be coated with red lead at


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three points, and 2 ~3 teeth shouldcoated at every point. Then rotategears clockwise and anti -clockwiseto get the trace of contact area (seethe right figure).The teeth area is not suit the figure(a)which should be adjust it .If thetrace is slanting to the convex orconcave then adding the shims ;ifthe trace is slanting to the convex orconcave ,then reducing the shims.Normal trace should be near thesmall end ,as figure (a):Add shim iftrace near the convex or concavetooth root ,as figure (b)Reduce shimif trace near convex or concave toothtop , as figure (c).Adjust the wheel hub bearing of rearaxle: to locking bearing and nut ,then

release1 31 4circle Tighten theforce moment to 490588N.m

Use & maintenance1Lubricate for hyperbola bevel gearis very strict, can be only specifiedgear oil. Don't use or mix with othergear oil, or will result in quickenedscratch and wear.2Don't remove or adjust the gears

and bearings of final drive, for theyhave been matched and adjusted infactory. Do these only when gearworn and free play is beyond thelimit value, or when bearing axialclearance is beyond the limit, orwhen some of parts damaged.3Clean the vent plug regularly,make sure that ventilation is expedite. A jammed air drain can bringhigher air pressure in rear axle, andit will result in lubricant leak from thedrive pinion seal and other weldingline.4Check the lubricant level in axlehousing regularly. Check the lubricant for quality regularly, and replaceif the chroma and viscosity is abnormal.

5Finished the third maintenance,disassemble the back cover .Thenclean cavity and main reducer axle .To tight the fore moment nut andblot.

VFrameThe brief of structure :This kind oftruck's chassis is across structureUse & Maintenance :Using longitudinal beam and cross beam is to fixedthe frame .Using weld and screwthread to connecting .So ,keep all theparts well to exerting the advantageof the frame .When doing the thirdmaintenance checking , if the screwsare lax that should be tight it. If thecross beam have something wrong ,should be mend it .The reason of damage the frame is

overweight , parking position androad and so on. .So ,must followingthe request to driving .

Suspension setGeneral Structure: The suspension ofthis series of trucks is composed ofmultiply variable leaf spring bidirectional hydraulic telescopic shock absorber and transverse stabilizer. Rearleaf spring is composed of mainspring and secondary spring, itsstiffness changes little by little, sothat vehicle is more comfortable forride.

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1. Front leaf spring 2. Front U bolt3. bumper 4. Front shackle5. Upper bracket of front suspension6. Front absorber 7.nut

front suspension assembly

1Frame 2Rear leaf spring3Rear center bolt 4Rear absorber5Secondary spring bracket6Rear shackle clamp

rear suspension assembly


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2. Use & Maintain leaf spring1)At the beginning of running-in period, check the nut on U -type fastening bolt and tighten it with specified torque when trochometer pointsto 200km and 500km.2)After running-in period, tighten thenut on U -type fastening bolt withspecified torque (with vehicle fullyloaded). Do it also when leaf springis replaced or reset.3)Tighten the nut on U-type fastening bolt with specified torque (withvehicle fully loaded) every 2000 ~3000km.4) The first maintenanceCheck andtighten bolts and nuts in your touchon suspension. Check the rubberparts on the suspension and replace

if too much wear.5At the second maintenance, doingthe first maintenance items .Thendisassemble and lubricant the springof plate , at the same time to checking anti-roll stabilizer .6At the third maintenance, doingthe second maintenance items . Thendisassemble all of the rubber tochanging the news.7)Take notice of the orientation whenreplace leaf spring or operate on thecenter bolt. Tighten each nut first,then tighten nuts on front U -typefastening bolt with specified torquebefore tighten the rear ones.

3. Use & Check absorber1 Check the absorber for temperature after running a length on bad

road surface (commonly more than10km). Absorber don't have resistance if the temperature lower thancondition temperature; if one absorber have much lower temperaturethan the symmetrical one, the lowerone's resistance is much moresmaller. Lower resistance result fromlack in oil or from damage of someimportant part, and the absorber thatlack in resistance should be removedto inspect.2 Check the absorber for oil leak ifcontinuous abnormal vibration is detected. Oil leak should be dealt withon time, so that the absorber canwork normally.3 Check absorber when maintainingvehicle. To check absorber, stick up

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it and hold its lower end by vise,then pull and press it for severaltimes. Normally the resistance isbigger when pulled, otherwise theabsorber is damaged or lack in oil.In the case , to changing and mending the parts ,then fill oil into shockabsorber .In order to absorber parts.4 Always replace the oil seal whenyou replace absorber rod. Don't disassemble parts such as valve if unnecessary.5At the third maintenance ,disassemble the shock absorber andchanging the new oil .Do not cleanthe shock absorber.

Front axle1. General structureFront axle assembly is composed of

front axle, steering knuckle, steeringknuckle king pin, hub and tie rod.See the next figure.The front axle is I -beam. The toeing-in is 3~6mm (diagonal tire) and1~3mm (radial tire). Proper orientation can make sure the vehicle stableand easy to control, so that canlessen driver's fatigue and slower tirewear.

2. Adjustment1) Adjustment of front hub bearing.To adjust front hub bearing in axialretightening force, tighten fasteningnut with wrench, and loosen knucklenut for about 120o. Rotate the hubclockwise and anti-clockwise, makesure that roller against the taperedface of bearing outer race properly,then tighten nut to the position wherethe rabbet aims the split pin hole.Check the hub if it can rotate freelyand don't swing a lot. Now, distortthe split pin and fix it.2) Adjustment of clearance betweenknuckle and front axle. The clearanceis adjusted via adjusting shim, itshould less than 0.1mm.3) Adjustment of toeing-in. The toe

1Front hub 2Brake drum3Steering knuckle 4King pin5Pitman arm 6Front axle7Tie rod

front axle assembly


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ing-in can be adjusted via adjustingtie rod. Park the vehicle on a flatground, jack up its header and orientfront wheels just as vehicle run forward. Loosen locking nuts of tie rod,rotate the tie rod utile the toeing-in fitthe specified size.

Use & Maintenance1) The first maintenance .When doingthe first maintenance ,check the nuttightly.2) When doing the second maintenance to checking damage aboutsteering knuckle , steering knucklearm ;to checking about steeringknuckle pin bearing ;to checkingabout the drag rod .According to theregulate ,disassembly wheel hub andfill grease with it.

3) when doing the third maintenance,to disassembly the front axle thencleaning and checking it.a) If the distance between steeringknuckle and front axle is very large ,should put a thrust shim on it to adjusting .The distance is 0.1mm to begood.b) When the steering knuckle pinand the bush's distance is 0.15mm,then to change new ones.The damage distance of the steering knucklepin is to 0.07mm,changing new ones.c) The damage of steering drag rodball end and ball end is too big ,thenchange the new ones.d) When find out the damage of oilseal of the wheel hub , then changethe new ones .

Steering systemGeneral StructureThe steering system of this series of truck is powersteering system.

Power steeringThe steering system composed ofsteering control mechanism, linkagemechanism whole power steeringgearpower steering pump andpipeline.The energy source of the steeringsystem is depended on driver'sphysical strength and power of engine .In some emergent cases aboutsteering system that the driver cancontrol the direction .To comparewith some common machine steeringsystem , the power steering systemis very sensitive and secure.

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Operation Inspection for SteeringMechanism1) Put front wheels on a swivel table.2) Rotate steering wheel clockwiseand anti -clockwise to its limit position, to detect if it is fluent.3) Let engine run in idle speed andcheck steering wheel for free play.The limit value of this free play is 15~35mm. Rotate the adjusting screwclockwise to decrease the free play,while rotate anti -clockwise to increase.4) When engine run in idle speed,the torque of steering wheel shouldbe around 19.6N.5)When staring the engine to turningsteering wheel to two sides for several times .When removing the air from

the engine ,then fill oil into it.6Turing the steering wheel to thefront.7Turn off the engine to checking oil.If it need oil, then fill it.Note:To checking is steering oil on ahigh temperature .If it has some troubles, then doing the 4 and 5 stepsagain or mending power steeringpump.

Use and Maintenace1 Check the new truck to driving for30004000km ,then fill oil to steeringand cleaning oil net.2 Always checking the oil measureor oil quantity in the oil crock, if it hassomething wrong that change it .3 Do not disassemble the steeringsystem for another side .Pay atten

tion to the oil pump pipeline ,it cannot fill with air in it .keep cleaning it.Step:a) Turn the steering out oil pump intothe steering in oil pump.b) The return oil inlet connect with oilcan inlet.4 In some troubles of power steering, the drive can use the handsteering but could not use for a longtime.5 Don't steer when parking, since itwill shorten useful life of parts.6 According to the regulate to fillhydraulic pressure oil, the environment temperature is above 0 ,change steering system shouldadopt L -HM 464# wear resistancehydraulic pressure oil; the environ


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ment temperature on 0 . (the different number oil can't mix an usage).The import power steering orsteering pump to choose to press oilwith the DEXRONII model numberliquid.(American G.M. standard)

The use and maintenance ofpower steering1)How to use of power steeringa) Don't steer when parking for 5minutes.b) Forbid to steer the steering wheelwhen can not moved.c) Forbid to steer the steering wheelin the same place.d) Forbid to steer the steering wheelspeed for 90turn/m.

2)How to maintenance of powersteering

The main idea is to prevent ,to checkfor scheduled time .Following aboutthe ministry of communications standard about the car JT T20195Thearts and crafts maintenance of carand city build ministry standardCJl786 The technique conditionmending way of the city bus.a)Daily maintenance: to checking thetruck when driving in order to yoursecurity.b)One class maintenance(2000-3000kms)i. Each lubrication partto fill thegrease, the power steering should befill the oil on time.ii. Insure cross shaft , cross/lax pullrodten ball end to moved vivid andnot loose.

iii. Check tight each conjunction part.iv. Check pipe conjunction part, insured and don't leak oil .c)Second class maintenance(10000-15000 kms)i. Chang the power steering oil.ii. Clean and check the steeringwheel.iii. Clean the power steering oil net.Iv Check front axle, ball axle, steering knuckle, steering knuckle arm,steering knuckle frname.v. Disassemble, length pull rod,cleaning and checking parts in orderto insure them well.vi.The other parts, please read thereference. (JT T 20195 )d)To install steering knuckle plumbing arm and locate blots. The daily

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maintenance:i. Insure the location. Find out steering knuckle plumbing arm is fall, thenput them on.ii. If the steering knuckle plumbingarm have some mistake, change thenew ones.iii. Tight the steering gear and frame,frame and frame blot.iv. When turning the direction, insurethe length pull rob and steeringknuckle plumbing arm do not intervene for each other.

IXBraking systemBraking systems of trucks of this series are: parking brake system(centerdrum) and running brake system (airbrake, hydraulic brake)

1. Running brake system1.1 Air brake1) Brief description of this system:Compared with hydraulic brake, airbrake can bring greater brakingforce under the condition that forceon the pedal is not great and thepedal stroke is not long; at the sametime, dual-circuit air-pressure driving braking device is equipped tofront and rear wheel separately, sothe braking is safe, reliable, labor -saving, and more effective; even ifone of the brakes does not work, thevehicle can still brake safely.2) Structure and theory (referring tothe following diagram)Brake pipeline is arranged as follows: compressed air produced by

air compressor 1 comes into themain air reservoir 3 (namely wet airreservoir); and then the air is separated into two and come into the frontchamber 9 of the auxiliary air reservoir and the rear chamber 4 of themain air reservoir, the front chamber9 of the auxiliary air reservoir and therear chamber 4 of the main airreservoir. Compressed air in the frontchamber 9 of the auxiliary air reservoir and the rear chamber 4 of themain air reservoir come into upperand lower chambers of brake valve8, and then the air is transportedseparately to rear brake chamber 12and front brake chamber 2. Checkvalves 10 installed on ends of the airinlet pipes of the front chamber 9 of


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the auxiliary air reservoir and the rearchamber 4 of the main air reservoir incase that compressed air in the airreservoir flows backwards. There areinterfaces for air pressure gauge 7and pressure -adjusting valve 6.When air pressure reaches 0.74 -0.84Mpa, compressed air props upvalve of the pressure -adjustingvalve, and comes into upper cover ofthe air compressor to make air inletvalve open and the air compressoridles. When brake valve 8 is depressed, front and rear brake chamber 2 and 12 operate at the sametime, which makes front and rearbrakes operate. When the brake pedal is released, compressed air infront and rear brake chambers go in

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

1. air compressor 2. front brake chamber 3. front cavity on main gas cylinder4. rear cavity on main gas cylinder 5. safety valve 6. pressure control valve7. barometer 8. brake valve 9. additional gas cylinder 10. one-way valve11. front quick-release valve 12. rear brake valve 13. rear quick-release valve

Interface for air inletInterface for low pressure

Interface for clutch

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Brake assemblyThe function of brake is to utilizepower produced by friction betweenbrake drum and brake shoe slice toabsorb kinetic energy of vehicle todecelerate or stop the vehicle. Frontand rear brakes of this brake systemadopt imbalanced structure and aremainly composed of brake chamber,brake arm and brake


1. return spring locating pin 2. roller shaft-brake shoe3. roller-brake shoe 4. gripping ring-brake shoe rollershaft 5/18. front brake shoe with liner assembly6/19. front brake friction plate 7. brake cam 8. front brake baseboard with liner assembly 9. front brake dust cap

10. hex bolt 11. front brake air chamber support frame with liner assembly 12. front left brake air chamber assembly13. hex bolt 14. front brake adjusting arm assembly 15. shoe shaft fixed bolt 16. front brake shoe-shoe shaft17. front and rear brake shoe shaft-liner 18. return spring

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Adjusting arm1Lubrication: mount oil month onadjusting arm, use lithium basegrease periodically to lubricate adjusting arm (maximum lubrication interval is limited to 10000km), or else,life of adjusting arm will decrease.2Check adjusting arm's counterclockwise force moment periodically:rotate adjusting nut of adjusting armcounterclockwise when running every20000km and measure whether therotary moment is bigger than 18Nm,measure for three times repeatedly. Ifthe moment is smaller than 18Nm, itindicates adjusting arm has beendamage and needs to be replacedthe adjusting arm assembly.

BrakeFront brake has the same structurewith the rear brake. It is shoe brakewith camshaft with fixed sustainer.When braking, front and rear shoeslices of the brake press to the rotating brake drum by the action of thesame push force; so the rear brakeshoe is called power-reducing brakeshoe. All above lead to imbalance offorces that front and rear brakeshoes press on the brake drum, sothis kind of brake is called simpleimbalanced brake.Clearance between friction disc of thebrake shoe and the brake drum mustbe proper, before adjusting the clearance, make the front wheel off ground;adjusting steps are as follows:

Full adjustment1. Loosening fixed nut of brake shoebearing pin and nut of binding bolton cam bracket.2. Rotate brake shoe bearing pin soas to make clearance between frontshoe and bearing pin end the sameas that between rear shoe and bearing pin.3. Start braking, make brake shoefriction disc lean against brake drumclosely and brake camshaft automatic positioned and tighten nut ofbinding bolt on support frame.4. Release braking and rotate wormso as to make brake shoe frictiondisc lean against brake drum closely.Then counter -rotate worm, releasedby 3/4r, brake drum should be rotate

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freely.5. Test drive after adjustment, checkworking condition of brake, whetherthe brake drum get hot and whetherbraking distance is proper. If not,readjust it

Parts checkingTo move the worm of brake arm toadjusting the distance betweenbrake assembly and brake drum .The way to the worm for clockwiseand move it again and again when itcan moved.Then move the worm forcouter -clockwise to 1 23 4circle.At last the drake drum work agility .The distance between brake frictionpiece and brake drum is 0.25c0.4mmcamshaft is 0.45mm.

Brake valveBrake valve is to adjust and controlthe whole brake system.Use and maintenance1)Take care of ita) Should check the tube pressurebefore driving, be air pressure measure is 0.6 MPa square can drive,while driving in normally is in the O.74 - 0.84 MPas,should park the carwhether leak air or not and whetherthe compressor normal work or not.b)When driving the truck to checkbrake system. If it has somethingwrong should be change it for another one.c)The damage of the brake shoeplate is too big, then changing another one. The piece should be the

same new ones and do not havedirty oil, shatter, chap.d)To change the friction and installshoe plate and brake cam again inorder to adjusting the friction pieceand the brake cam.2)Shedule time maintenance:a) The first maintenance (1500-2000kms)i. To excluding the oil from the gascylinder.ii. To fill with grease where need it.iii. To checking and adjusting thetighten about air compressor .b) The second maintenance(1000012000km)i. Disassemble and adjust the brakeand adjust the distance betweenbrake shoe friction piece.


ii Check the air compressor andclean the dust of air valve.iii. Check the brake involucra whichneeds news to changing it.c) The third maintenance (2400030000km)i. Check and adjust the brake valve .When it need new one then change itii. Check the brake valve pipe .When it need new one then change itiii. Clean all the pipe in order to keepit liquidity.

1.2 Hydraulic brake system

1) General StructureThe running brake system is hydraulic. It is composed of vacuum

booster, vacuum cylinder, mastercylinder, control mechanism, braketube, front brake and rear brake. It issensitive and reliable, and it is simple to manipulate. See the last figure.If you feel braking power is not sufficient when brake pedal is depressedcompletely 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 RFbrake; then bleed LF brake. Followthese steps:a. Clean air -drain screw of maincylinder and wheel cylinder;b. Remove oil -drain plug of maincylinder or reservoir and fill it withbrake fluid until fluid level reach the

1Control mechanism2Vacuum booster3Master Cylinder 4Reservoir5Vacuum cylinder 6Brake tube7Front & Rear brake

the picture of running brake

connect to enginevacuum pump

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edge.c. Depress the brake pedal severaltimes before hold it depressed andrelease the air-drain screw to bleed.Repeat doing this until air in tube bebled completely. Keep a little oil left,or air can reenter the system.d. Fill reservoir with brake fluid.

2) Note When Use Brake Fluid The specified brake fluid of thisseries truck is synthetic brake fluid ofclass JG3 (GB10830). Never use mixed brake fluid. Synthetic brake fluid is good atsopping up. They should be storagein a clean sealed dry container, keepaway from water, organic solvent,petroleum, and dust. Otherwise thevehicle's capability of brake wouldbe cut down seriously. Clean system with alcohol beforereplacing brake fluid with differentbrand. Follow these if alcohol is unavailable.a. After drain all old brake fluid, fillreservoir with new fluid near to theopening and bleed system again, in

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schematic diagram hydrostaticbrake system

1. Brake pedal 2.Vacuum boosterand main cylinder assembly

3.Reservoir 4. Connection hose5.Rear brake 6.Vacuum cylinder7.Intake manifold 8.Front brake9. Vacuum check valve10.Connect to vacuum-alarmhydraulic tube vacuum tube

order to sweep old fluid away.b. Fill system with brake fluid. Brake pedal's free play should be5 ~8mm after adjusted, or it willcause main booster work abnormallyand make brake drum over hot.

Running brake1) General StructureThe running brake is hydraulic drum,both front and rear is two leadingshoe brake. It is composed of bottomplate, wheel cylinder, brake shoe setwith pad, and return spring set.2) Adjustment of Running BrakeThe clearance between pad anddrum will be bigger and bigger dueto wear. In order to ensure brakework well, adjust it regularly followthese steps.

Jack up the wheel which you want toadjust and remove the seal plug. Dialthe adjusting gear of wheel cylinderpiston accord the arrow near the adjusting hole on bottom plate withspecial adjusting screw and at thesame time rotate the brake drum untilthe drum can not rotated by hands.Then rotate the adjusting gear backfor 5 ~9 teeth, keep the pad 0.2 ~0.45mm away from the drum, so thatthe drum can rotate freely again.3) Use & CheckReplace the pad which is worn out ordamaged. Before installed, the newpad should be ground. Make surethat the new pad has not oil coat, also has not crack and chap and otherflaw.

The clearance should be adjusted inevery time of maintenance. Checkdrums with hands for temperature every time you park, adjust the clearance if the temperature is too high.Check wheel cylinders for leak, andreplace the leather gasket if leak isdetected. Protect drums from beingwrong result from over heat and other reason.

Vacuum booster1) General StructureBooster of this series of truck is dualdiaphragm vacuum booster, which iscomposed of return spring, controlvalve, rubber diaphragm, noise elimination board, and so on.2) AdjustmentBooster have been adjusted in fac

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

1.3 Parking brake system

parking brake systemcontrol mechanism

The parking brake system includescontrol lever, pull wire, and parkingbrake, as the last figure. Parkingbrake, which is mounted next totransmission, is center drum brake. Itcan act on drive shaft when vehicle

is parking. Also it can operate withrunning brake together in emer -gence.2) AdjustmentNormally, the clearance betweenparking brake drum and brake padis 0.65mm, and it is homogeneous inupper and lower parts. The padshould be replaced often. Followthese steps.a. Jacking up rear axle until onewheel deviate from ground.b. Release the brake handle com -pletely, shift gears to neutral position.c. Rotate brake drum until the holegets its lowest position. Insert ascrewdriver through this hole to stirthe adjusting nut upward until brakedrum braked completely

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

adjustment of the clearance betweenbrake pad and drum

Use & Check:Check and adjust the clearancebetween brake pad and drum.

1Control lever 2Pull wire3Frame 4Parking brake

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Wheel & Spare wheelriserGeneral structureEvery truck hasseven wheels, one of which is sparetyre.Use & Check:In order to use for a longer time,please charge tire according tospecified pressure value. Never drivewhen pressure is insufficient. It isnormal that pressure increasesduring travel, and don't try to reduceit by deflating. Check the tirepressure when tire is not hot. If thetwo center patterns on tire treadtouch against ground under fullyloaded, the pressure is normal.Clean the rust and other dirty on rim

before installed. It should be talcedon the surface between inner tubeand outer tire. Wheel nuts should betightened for two steps. Tighten all ofthem first before tighten them withspecified torque according to diag-onal sequence.

In order to make tires wore uniformly,exchange wheels each other accor-ding to the figure.

2. Spare wheel riser1) General Structure & UseThe spare wheel riser is driven bycatenary suspension internal gearedwheel, see the next figure. It ismounted underneath the frame. Tooperate it, fix it on the frame andtighten it with hand before rock backfor 15 degree.2) Maintenance of RiserCheck riser for loose every timebefore drive. Check chain and carrierspring for crack and replace ifnecessary. In order to prevent it fromrust, grease the gearing regularly, sothat it can be easy to operate.The third maintenance, should beprepare wheel.Then cleaning,check-ing ,install it again.

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1Frame 2Spare wheel riser assembly 3Eccentric wheel4Spare wheel 5Chain 6Carrier

spare wheel riser set

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IVElectrical equipment() Starter

() Generator and adjuster

() Illumination equipments() Battery

() Sensor

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Use the measuring cell to testing.Put the car and the measuring cell

for a line, from measuring cell screento testing left, right, the far and nearlight beam to project light upon directions to be partial to move a valuerespectively.To adjusting the headlight' the uprightess and the level. To adjustingthe passing beam , make it match diagram the shining area center re

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

2. Small lightTwo small lights are embedded onthe two symmetrical corner of frontpanel. They should be turned on

Right ScreenLeft

Left Right

10 m

headlamp(old series)

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

()Generator and adjusterNote:

1) Generator should be connectedwith adjuster correctly, and the polarities of generator and adjuster

should be matched properly.2) Never check generator by short-circuit fire wire and magnetic field.3The diode and insulation of generator can be inspected with multimeter and ohmmeter. Don't usemegohmmeter to inspect, also ACpower whose voltage exceeds 200v.

() Illuminate equipments1. HeadlampThis series of truck have two headlamps which are embedded in frontof cab symmetrically. The headlampwhich is called double filament bulbhas two different pieces of filamentand can shine two different kinds ofray, the brighter one is used as highlamp while the dimmer one is usedas low lamp. Running in night, turn

on the high lamp to lighten the road,but switch to low lamp when two vehicles pass each other.In order to see the road clearly ,when you stripping and re-assemblyheadlight that you sould be adjustement the position . The way is to putthe car on a evenly road then put ascreen in front of the car. The distance between the car and thescreen is about 10meters.(as picture)

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headlamp(new series)


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pacitance into battery. Cut down thecharging current for half after singlecell's voltage reaches 2.4V. Aftercharging battery for 3~5 hours, if thespecific gravity of electrolyte don'trise any more, keep on charging for2~3 more hours. Table 2 shows therelationship between temperatureand the corrected specific gravityvalue of electrolyte.6)Protect the joint of terminal postand wire from dirt and loose, or theterminal post will be burnt. Applyinga Vaseline coat on the terminal postafter tighten the joint which can protect joint from rust and loose contact,so that engine can be started easily.7)If left unused for a long time, battery should be removed and pre

served in a place where is dry,shady, cool, and ventilative And dothe additional charging every month.

()Sensor1. Fuel level gauge sensorThe fuel level sensor is sliding resister. Floating on the fuel level, thefloat rises and drops with the level'schange. This change causes the resister connected in circuit and shorted, and make the electromagnetic fuel level gauge changes. Connectingthe fuel level alarm lamp's terminalwith the indicator light can shows thelowest fuel level.

2. Water temp sensorThe temp sensor is a thermistorwhich is mounted in water jacket todetect the temp of cooling water. It isconnected with the water tempgauge on instrument board. The wa

Loca

Specific gravity offully charged battery under 15

Where temp above -30 in winter 1.290 1260Where temp above -20 in winter 1280 1250Where temp above -10 in winter 1270 1240Where temp below 0 in winter 1270 1240

Winter SummerWhere temp below -40 in winter 1310 1270

Table 1 Specific gravity of electrolyte

Measured tempof electrolyte

+45+30+15 0 -15-30-45

Corrected valueon hydrometer

+0.02 +0.01 0 -0.01 -0.02 -0.03 -0.04

Table 2 Corrected specific gravityvalue of electrolyte under 15

when vehicle park in dark or fog, also when run in day to show the position and the width of the vehicle.

3. Fog lampFog lamp can light further in fog thanother lamp. They should be turnedon when vehicle run or park in fog orin dark, so that vehicle can be seenclearly. Fog lamp is combined withheadlamp.

4. Ceiling lampThe ceiling lamp is installed on theceiling, and it is combined with inside rear mirror together. It can lighten the cab, and also it can observethe condition behind.

()Battery1. General

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

2. Use & Note1) Keep the case clean, and protectbattery from leak.

2) Make sure that the hole on theupper cap not choked, or the platewill be damaged by the vapor produced own to electrolyzing.3)The electrolyte level should be 10~15mm higher than plate. Only distilled water can be filled into battery.

Never fill battery with fountain or riverwater, for them will do harm to it.4)Check the electrolyte for specificgravity and level. Do it every 10~15days in winter, while do it every 5~10days in summer. Specific gravity ismeasured with gravimeter. Table 1shows normal specific gravity ofelectrolyte.5)The battery should always beingcharged. Check battery for electricalvoltage if engine is hard to be started. Additional charging if it is detected that specific gravity of electrolytelower than 1.18 ~1.20, or batteryplates will be vulcanized and it willdo harm to the plates. Additionalcharging should be held for 13 ~16hours, and it can breathe 1/10 of ca

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Vehicle service and maintenance() Notice during running-in period

() Daily maintenance

() Second-class maintenance

() Seasonal maintenance

ter temp sensor has a negative temperature coefficient and its resistancedecreases with the increase of watertemperature. Don't replace the sensor with a positive temperature coefficient one, or the water temp gaugecan not work correctly.

3. Oil pressure alarmOil pressure alarm is a normal closedswitch. It will be opened when oilpressure reaches and over the lowest pressure, so that circuit is disconnected and indicator goes out.

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well. Don't drive in high speed whenthe temp is below the normal temp(between 80oC and 90oC).5) Regularly check the engine cylin-der cover, wheel nuts, car body, andthe U-bolt of leaf spring for tighten.Check the steering system, brakesystem, and clutch for normal oper-ation. Check steering wheel for freeplay. Check the brake pedal andclutch pedal for operating stroke andfree play.Note: Cylinder cover bolts should betightened twice when the cylinder iscool,according to diagonal sequencefrom the center to sides.6) The oil should be replaced after500km1000km 2500km (do it whenengine is hot), then it will be repl -

aced again in second -class main -tenance.

3. After running-in period1) Replace engine oil and oil filtercore. Replace oil in transmissioncase and rear axle, and replacelubrication in steering gear, also hubbearing grease.2) Check all external bolts and nutswith specified torque.3) Apply grease on all points whereshould be lubricated.4) Do items of first -class mainten -ance.

Daily maintenameWhen you find out some mistakesabout the trucks, you must checkand resolve it at the first time. It isvery important to do periodical

service for the truck. As a result ofthe area and periodical service aredifferent, so you should be take careof the truck to periodical service.The following references is how totake good care of the chassis. Doesnot introduce about the seasonservice.User can follow the basisabout area to do season service.Everyday routine maintenanceEveryday you do not use the truck ,you may check about it, in order tohaving a good technology.1.To checking the engine and fill withrust prevention and antifreeze oolant.In winter,let out water from theengine.If you want to using antifreezecoolant that you must follow the airtemperature.

I Notice during running -in periodTo improve vehicle's reliability andeconomical efficiency and also to useit longer, follow these during running-in period which is specified as about2500km.1. Before running-in period1) Wa sh vehicle with water, andcheck all bolts and nuts for tighten.2) Check the radiator for enoughwater,and check the engine,transmi-ssion, rear axle, and steering gearbox for enough lubrication,also checkbattery and reservoir for liquid level.3check brake systemdrive system,and steering system for correctoperation.4) Check electrical equipments and

lamp instruments for correctoperation, and check brake systemfor normal air pressure.5) Check the shift gears for right; thecontrol parts for normality, transm -ission for shifting smoothly, and theindicator should works correctly.6) Check tires for proper air pres -sure.7) Check that if driver tools andaccessories are taken.

2. During the running-in period1) The new truck should run onsmooth road, and don't make it loadmore than 50% of its rated loadbefore it traveled 800km and don'tload more than 75% before 1500km,or it will shorten truck's life and bringdriver danger.

1)Put so many goods in the trucks ,itwill be curtail the car's life and alsoinfluence your safety.2) Don't run faster than the followspeed.First gear 7km/hSecond gear 14km/hThird gear 26km/hForth gear 40km/hFifth gear 56km/h3) At the beginning, check the rearaxle, transmission case, driveshaft,and brake drum for temperature.Give ear to the sound of chassiswhen driving and stop to inspect ifabnormal noise is heard, then shoottrouble before drive again.4) Both the cooling water temp andoil pressure should be noticed very

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2.To checking the measure lubricantoil of the engine.3.To checking the degree of tensionand measure of injury about the fanbelt.4.To checking brake system when itwas working or sealing the atmosph-eric pressure (hydraulic pressure)and pipe line.5.To checking the work aboutdirection system circumstance,whether each bolt and the nut hasn'tloosen to move.The cotter pin is verytight.6.To checking weather the springabout armor plate7.To checking the atmospheric pres-sure of wheel.To finding where isharmful position about the wheel and

nut.8.Notice to fill water to the airreservoir everyday.

( )Second-class mainte-nanceWhen the ne w car was driving forone period which should take dailycare and scheduled care.In order tounderstanding the basis usage andthe technology.The car drive on acommon road,the second mainten -ance mileage is 15000 kilometers.The car is going to do the secondmaintenance,you can come to JACSpecial Repair Shop and we will tryour best to help you.

Seasonal maintenanceIn order to keep some parts meet therequirements of climate on aspects

of technique and work request, doseasonal maintenance.At the beginning of summer:1. Cleanout water scale in the coolantsystem.2. Replace lubrication for summer.3. Fueling with #0 diesel oil specifiedin GB252.4. Clean up the battery and adjustthe specific gravity of electrolyte.At the beginning of winter:1. Clean up the batte

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