JAC Light truck HFC1040. Service Manual — part 3

67

Trouble symptom and probable cause

Checking and remedy

(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

(2)Insufficient electric capacity

(a) New battery without circulation of charge and dis鄄

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

1援Electrical parts trouble shooting

66

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鄄
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鄄
quipped.

Checking and remedy of electri鄄
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

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鄄
place. If still not bright, explain the
index sign lamp bulb burn bad,
should replace, perhaps is launch
the engine oil road contain break鄄
down.
Dynamo is not work
Dynamo is work well, but indicator
light is not work.The main cause of
lamp connection is not well.

HFC1048

series trucks

69

2. Clutch trouble shooting

Trouble symptom and probable cause

Checking and remedy

(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

(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

Trouble symptom and probable cause

Checking and remedy

渊3冤Too much waste of electrolyte

(a) High charging amperage. Elactrolyte vaporize or ov-

erflow

(b) Leak battery

渊a冤Reduce the frequency of starting and shorten the start鄄
ing time .Decrease amperage of charging current
渊b冤Replace cover of the battery.

渊4冤Self-discharge of battery

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

渊d冤Dire external surface of battery case .Metal impurities

mixed into electrolyte

渊a冤Clean the output cable ,dispose the short
渊b冤Check and repair
渊c冤Check and repair
(d) Clean the battery case .Tighten shield .Replace elec鄄
trolyte if necessary

HFC1048

series trucks

70

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

a. Adjust to 3~5mm

b. Replace

c. Replace

d. Replace

(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

HFC1048

series trucks

71

Trouble symptom and probable cause

Checking and remedy

(1) Noise or vibration of driveshaft

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鄄
sembly
b. Align or replace
c. Retighten
d. Replace
e. Fill up after cleaning

(2) Overheating center bracket

a. Too much tight of oil seal

b. Too bigger a inclination between drive shaft and

crankshaft

c. Insufficient lubrication

a. It will disappear along with travel longer
b. Check and adjust the inclination

c. Fill up regularly

3援Drive shaft trouble shooting

72

Trouble symptom and probable cause

Checking and remedy

(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
g. Worn or damaged synchronizer hub and engagement

sleeve

h. Worn or damaged bearing of input shaft and output

shaft

i. Worn or damaged thrust ring and thrust washer
j. Loosen bolts which mount transmission to engine

a. Replace the coupling
b. Tighten
c. Readjust
d. Repair or replace parts
e. Replace shift fork
f. Replace
g. Replace

h. Replace bearing

i. Replace
j. Tighten

4. Transmission trouble shooting

HFC1048

series trucks

73

Trouble symptom and probable cause

Checking and remedy

(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. Adjust shift knob
b. Replace
c. Replace
d. Check and tighten

(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

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

(3) Noise from transmission

a. Loosen bolts which mount transmission to engine
b. Worn gear or bearing

a. Tighten
b. Replace

74

Trouble symptom and probable cause

Checking and remedy

(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

(2) Abnormal worn tire

a. Improper position fix of front wheel
b. Improper pressure of front 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

a. Adjust, and replace if necessary
b. Adjust, and inflate

5尧Front axle trouble shooting

HFC1048

series trucks

75

Trouble symptom and probable cause

Checking and remedy

渊3冤Vibrate oscillate

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

渊a冤front wheel location is wrong
渊b冤damage of the main bush
渊c冤the tight of wheel hub is wrong
渊d冤damage of wheel hub axle

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

渊b冤replace
渊c冤adjust
渊d冤replace

76

Trouble symptom and probable cause

Checking and remedy

渊e冤cross pull rod ball end is loosen
渊f冤U type of nut and blot are loosen
渊g冤the nut of wheel hub are loosen
渊h冤the distortion of wheel
渊i冤the wheel are not imbalance
渊j冤the wap of wheel
渊k冤shortage of the air pressure

渊4冤leak grease from wheel hub
渊a冤damage of oil seal
渊b冤hub cover is loosen
渊c冤too much grease

渊e冤change the parts
渊f冤tighten
渊g冤tighten
渊h冤replace
渊i冤adjust the balance
渊j冤adjust
渊k冤adjust袁charge air

渊a冤replace
渊b冤tighten
渊c冤use grease to fix

HFC1048

series trucks

77

Trouble symptom and probable cause

Checking and remedy

(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
j. Loosen tightening bolts of ring gear
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

6. Rear axle trouble shooting

78

Trouble symptom and probable cause

Checking and remedy

(3) Hot rear axle

a. Oil leak because of damaged seal gasket, loosen oil

drain plug, and jammed vent hole, result in insufficient lu鄄
brication

b. Bad lubrication

c. Tight over between pinion and driven gear, tight over

on bearing

a. Fill up and readjust

b. Replace lubrication accord the season
c. Readjust

p. Loose tightening bolts of differential case
q. Insufficient oil
r. Bad oil

p. Tighten
q. Fill up
r. Replace

(2) half shaft seal Leaking

a. Jammed rear axle vent hole
b. Bad lubrication

c. Tight between pinion and driven gear, tight bearing,

and tight over on bearing

a. Fill up and readjust
b. Replace lubrication accord the season
c. Readjust

HFC1048

series trucks

79

Trouble symptom and probable cause

Checking and remedy

(2) Shake of steering wheel, instable steering

a. Loosen steering linkage mechanism
b. Unbalance front wheel
c. Pendulate too much
d. Damaged grinding wheel

e. Heavy wear or too big clearance of steering linkage

mechanism

a. Tighten properly
b. Balance the wheel
c. Adjust
d. Replace
e. Replace parts

(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

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

e. Inflate properly

7. Steering mechanism trouble shooting

80

Trouble symptom and probable cause

Checking and remedy

(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

(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

a. Adjust the brake clearance or replace damper
b. Inflate tires
c. Check front spring assembly
d.Adjust or replace
e. Readjust

(4) Power steering bump leaking

a. Damaged oil seal or O ring
b. Damaged oil seal locking nuts or oil-drain plug

a. Replace
b. Repair

HFC1048

series trucks

81

Trouble symptom and probable cause

Checking and remedy

渊2冤brake moment is partial

渊a冤brake shoe plate unseemliness
渊b冤one side of brake shoe plate is rustiness
渊c冤shoe plate have oil dirt
渊d冤the wheel is empty.
渊e冤brake drum is change

渊a冤adjust
渊b冤grease
渊c冤clean
渊d冤ordain air press
渊e冤adjust and grind

(1)shortage of brake

渊a冤adjust the brake room
渊b冤have some dirty things
渊c冤brake cam and shoe brake are rustiness
渊d冤brake room epithelia and pipe are leak air
渊e冤brake valve lead air

渊f冤the distance between brake and shoe plate is too large

渊g冤brake drum
渊h冤have dirty things on the pipe
渊i冤enter air to brake valve is slowly

渊a冤adjust the pull rod
渊b冤use buck to washing
渊c冤clean the rustiness and grease
渊d冤change epithelia ,check the air part
渊e冤change valve base
渊f冤adjust
渊g冤adjust and change
渊h冤clean it
渊i冤check enter air of the karat

8. Running brake trouble shooting

83

Trouble symptom and probable cause

Checking and remedy

(3) Bad absorption

a. Insufficient damping fluid
b. Having no maintaince regularly
c. Damaged rubber collar

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

(1) Broken leaf spring

a. Load too much or partial to one wheel

b. Frequent emergency brake, drive too fast on uneven

road

c. Loosen U-bolt. Loosen or broken spring clamp
d. Failed damper

a. Load properly as rated
b. Keep your mind on driving, so that avoid emergency
brake and slower speed on uneven road
c. Tighten U-bolt. Tighten or replace spring clamp.
d. Repair or replace

2) Noise in driving

Check and replace rubber suspension part

10. Suspension trouble shooting

82

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

9. Parking brake failure shooting

HFC1048

series trucks

84

Trouble symptom and probable cause

Checking and remedy

(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

e. Frequent emergency brake, flare up when starting, or

accelerate suddenly

f. No wheel transposition

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. Drive stably, don't drive too fast

f. Transposition regularly

11. Wheel trouble shooting

HFC1048

series trucks

85

No.

1

Vehicle type

HFC1048K

type truck

Engine type

YZ4102QF
YZ4105QF

CY4102BQ

Inside dimension

of the cargo body

(l伊w伊h)

渊mm冤

4130伊1960伊400

Axle
Base

(mm)

3308

2

HFC1048KR1

type truck

3800伊1960伊400

3308

3

HFC1048K1

type truck

CY4102BZLQ

YZ4102ZLQ

4130伊1960伊400

3308

Outside dimension

(l伊w伊h)

(mm)

5910伊2096伊2250

5910伊2096伊2250

5910伊2096伊2250

Engine

power

(ml/kW)

3856/70.6

4087/75

3856/70.6

3856/88
3432/81

4

HFC1048K1R1

type truck

CY4102BZLQ

YZ4102ZLQ

3800伊1960伊400

3308

5910伊2090伊2250

3856/88
3432/81

5

HFC1048KD

type truck

CY4102BZLQ

CY4102BZQ

3856/88
3856/88

5910伊2096伊2250

4130伊1960伊400

3308

喻尧Automotive model table of trucks

86

No.

6

Vehicle type

HFC1048KR1D

type truck

Engine type

Inside dimension

of the cargo body

(l伊w伊h)

渊mm冤

3800伊1960伊400

Axle
Base

(mm)

3308

7

HFC1048K8

type truck

4130伊1960伊400

3308

8

HFC1048K8R1

type truck

CY4102BZLQ

YZ4102ZLQ

3800伊1960伊400

3308

Outside dimension

(l伊w伊h)

(mm)

5910伊2090伊2250

5910伊2096伊2250

5910伊2090伊2250

Engine

power

(ml/kW)

3856/88
3432/81

9

HFC1048K9

type truck

HFC4DA1-1

4130伊1960伊400

3308

5910伊2096伊2250

2771/68

10

HFC1048K9R1

type truck

HFC4DA1-1

2771/68

5910伊2096伊2250

3800伊1960伊400

3308

CY4102BZLQ

CY4102BZQ

CY4102BZLQ

YZ4102ZLQ

3856/88
3856/88

3856/88
3432/81

HFC1048

series trucks

87

No.

1

Umber of

leaf springs
(front/rear)

12/14

tyre

Max load

capacity

(kg)

1920

2

12/14

1920

3

12/14

7.00-16

1725

Cross vehicle

weight

(kg)

4480

4480

4480

Tread

(front/rear)

(mm)

1665/1525
1665/1485

4

12/14

7.00-16

1725

4480

1665/1525
1665/1485

5

12/14

7.00-16
7.50-16

1665/1525
1665/1485

4480

1725

7.00-16

7.00-16

1665/1525
1665/1485

1665/1525
1665/1485

Curb

wigh

(kg)

2560

2560

2560

2560

2560

Front/rear
suspension

(mm)

23/14

1105/1497

23/14

1105/1497

23/14

1105/1497

23/14

1105/1497

23/14

1105/1497

88

No.

6

Umber of

leaf springs
(front/rear)

12/14

tyre

Max load

capacity

(kg)

1725

7

12/14

1725

8

12/14

7.00-16

1725

Cross vehicle

weight

(kg)

4480

4480

4480

Tread

(front/rear)

(mm)

1665/1525
1665/1485

9

12/14

7.00-16

1790

4365

1665/1525
1665/1485

10

12/14

7.00-16

1665/1525
1665/1485

4365

1785

7.00-16
7.50-16

7.00-16

1665/1525
1665/1485

1665/1525
1665/1485

Curb

wigh

(kg)

2560

2560

2560

2380

2380

Front/rear
suspension

(mm)

23/14

1105/1497

23/14

1105/1497

23/14

1105/1497

1185/2050

1185/2050

HFC1048

series trucks

89

峪尧Appendix

Main lubricating position and the lubricant name(for reference)

Description of the oil in lubricating table (for reference)

Main files along with the vehicle

90

No.

1

8

Lubricating position

universal joint of the driveshaft

Filer cartride

Symbol of

the lubricant

G

Number of

the ubricating

3

1

2

spline of the driveshaft

G

1

fill

3

battery terminal

G

2

fill

4

transmission

Z

6L渊reference冤

fill

5

oil cup of the clutch brake

master cylinder

Y

suitable

one change one year

6

steering gear

Z

1

7

steering knuckle pin and ball pin

of the drag link and the tie rod

G

各

2

check

fill

fill

replace

replace

replace

replace

replace

replace

replace

replace

maintenace cycle

everyday

First

time

Seconde

time

Third

time

Every

season

Table one

Main lubricating position and the lubricant name(for reference)

HFC1048

series trucks

91

No.

9

Lubricating position

generator

Symbol of

the lubricant

G

Number of

the ubricating

2

fill

10

Power steering

D

1

11

bearing of the front尧rear hub

ZL

Each 2

12

Shack absorber

Q

2

13

Water pump bearing

G

1

14

Transimission drive

gear front bearing

G

1

15

Rear axle

Z

1

fill

fill

replace

replace

replace

fill

replace

replace

maintenace cycle

everyday

First

time

Seconde

time

Third

time

Every

season

16

Engine lubrication system

1

fill

replace

replace

17

Cooling system

drive mechanism

ZL

2

fill

fill

fill

92

Symbol in the

table

B

D

Lubricant

L-BCD4 oil GB11123渊summer冤袁LECD30 oil GB11123渊winter冤

L-HM46(GB11119), the below zero is L-LM32(GB11119) antiwear hydraulic oil.

J

15W/20 or 15W/40 thickened oil

G

GB49 2# lime base grease

ZL

GB5671 universal lithium base grease

Q

Half HU-20 gasoline engine oil渊GB2537冤and half 45# transformer oil 渊GB2536冤

Y

brake fluid JG3渊GB10830冤

Z

medium-load vehicle gear oil渊GL-4冤 85W/90

Table two

Description of the oil in lubricating table (for reference)

HFC1048

series trucks

93

Number

1

2

3

4

5

6

7

Name

Tightening torque渊N窑m冤

Nuts of steering tie rod ball pin

186依20渊19依2冤

Nuts connected the transmission and the clutch housing

68.8-93.2渊7-9.5冤

Intermediate driveshaft flange nuts

343-539渊35-55冤

tyer nut

196-245渊20-25冤

Diving gear flange nuts

220-250渊23-25.5冤

Fixing nuts of the steering straight arm

441依49渊45依5冤

U-bolt of the front leaf spring

250

8

U-bolt of the rear leaf spring

350

9

steering fix bolt

68.8-88.2渊7-9冤

10

Fixing nuts of steering flexural arm

441依49渊45依5冤

11

Steering-wheel fix nut

49-78.4渊5-8冤

12

Transmission flange nuts

>166.7渊17冤

13

Pitman arm shaft nut

196-235.2渊20-24冤

Table three

Tightening torque of main fastening pieces (for reference)