JAC Light truck HFC1020. Service Manual — part 3
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
d. Brake cable's maladjustment, break joint, or circlip
drop out
a. Adjust the clearance until both its upper and lower is
0.65mm
b. Clean with water
c. Replace
d. Adjust, weld the joint, install a circlip
Parking brake failure shooting
70
HFC1020
series trucks
Running brake trouble shooting
Trouble symptom and probable cause
Checking and remedy
2. Bad brake effect
a. Big pedal free play
b. Air in brake system, oil leaking from the joints, or
jammed brake tube
c. Improper clearance between brake pad and drum
d. Jammed piston in wheel cylinder or main cylinder
a. Adjust until it is 5~8mm
b. Bleed system, deal with leak, or repair
c. Adjust the wheel cylinder piston
d. Repair or replace
1. Running brake failure
a. Crack of brake hose or tube
b. Failed valve in master cylinder
c. Failed vacuum parts
a. Repair or replace
b. Check and replace
c. Check the check valve and vacuum pump for leak;
Weld the vacuum pump, replace joints of hoses and
tubes
71
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Trouble symptom and probable cause
Checking and remedy
4. Hot brake
a. Small clearance between brake pad and drum
b. Broken or failed return spring
c. Swelling leather ring in wheel cylinder
a. Adjust
b. Replace
c. Replace
3. Wander when brake
a. The clearances between brake pad and drum are not
equal from wheel to wheel
d. Distorted brake drum
c. Oil coat on brake pad or drum
d. Unequal tire pressure
e. Broken return spring
f. Swelling leather ring in wheel cylinder
g. Distorted frame, disalign front suspension, or improp鄄
er orientation of front wheel
a. Adjust clearances to the same
b. Replace
c. Snag the brake pad with emery cloth after clean it with
petrol or soda water
d. Inflate by specification
e. Replace
f. Replace
g. Repair, replace, or dispose by fitting way
72
HFC1020
series trucks
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
Wheel trouble shooting
73
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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
Suspension trouble shooting
74
HFC1020
series trucks
Trouble symptom and probable cause
Checking and remedy
4. Self-discharge of battery
a. Battery output cable short to ground
b. a short circuit between pole plates
c. Damaged or breakdown cell divider
d. Dirt external surface of battery case. Metal impurities
mixed into electrolyte
a. Clean the output cable, dispose the short
b. Check and repair
c. Check and repair
d. Clean the battery case. Tighten shield. Replace elec鄄
trolyte if necessary
1. Horn brows continuously
a. Incorrect connection
b. Failed grounding or spring in circuit
a. Check and connect again
b. Disassembly 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
form vehicle
3. Too much waste of electrolyte
a. High charging amperage. Electrolyte vaporize or
overflow
b. Leak battery
c. Damaged or breakdown cell divider
a. Reduce the frequency of starting and shorten the start鄄
ing time. Decrease amperage of charging current.
b. Replace battery case
c. Check and repair
Electrical parts trouble shooting
75
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No.
Max load
capacity
1
1500/1800/1700
Vehicle type
HFC1020K
type truck
Engine type
YSD490Q
Overall size
(l伊w伊h)
(mm)
5270伊1868伊2100/
5090伊1868伊2100
Rear body size
(l伊w伊h)
渊mm冤
3580伊1770伊370/
3330伊1770伊370
Tyre
6.50-15/
6.50-16
Wheel
base
(mm)
2600/2800
1500
YND485Q
5090伊1868伊2100
3330伊1770伊370
6.50-16
2600
YND485Z
5090伊1868伊2100
3330伊1770伊370
2600
6.50-15
1500
HFC4DA1
5400伊1868伊2200
3580伊1710伊370
2800
6.50-16
1700
2
HFC1020KR1
type truck
YSD490Q
5090伊1868伊2100
5270伊1868伊2100
3000伊1770伊370/
3580伊1770伊370/
3250伊1770伊370
2600/
2800
6.50-15/
6.50-16
1500/1800/1700
YND485Q
5090伊1868伊2100
3000伊1770伊370
2600
6.50-16
1500
YND485Z
5090伊1868伊2100
3000伊1770伊370
2600
6.50-15
1500
HFC4DA1
5400伊1868伊2200
3250伊1710伊370
2800
6.50-16
1700
3
HFC1020KW1
type truck
YZ485ZLQ
YD480Q
4660伊1742伊2100
2920伊1600伊350
2400
6.00-14
980
4
HFC1020KWD
type truck
YD480Q
4660伊1742伊2100
2920伊1600伊350
2400
6.00-14(single
rear tire)
980
77
Appendix one
Automotive model table of HFC1020 series trucks
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Appendix two
Lubricating table of the entire vehicle and tightening torque table of main fastening pieces
Table one: Main lubricating position and the lubricant name(for reference)
No.
Remark
1
8
Lubricating position
front尧rear leaf spring pin and shackle pin
clutch pedal shaft and brake pedal shaft
Symbol of the
lubricant
G
G
Number of
the ubricating
point
Dosage for
each vehicle
2
4
2
universal joint of the driveshaft
G
3
3
spline of the driveshaft
G
4
4
supporting bearing of the intermediate driveshaft
ZL
4
5
battery terminal
H
4
suitable
6
transmission
Z
1.7L
7
oil cup of the brake master cylinder
Y
4
78
HFC1020
series trucks
No.
Remark
9
19
Lubricating position
steering knuckle pin and ball pin of the drag link
and the tie rod
engine
Symbol of the
lubricant
G
J
Number of
the ubricating
point
Dosage for
each vehicle
each 2
1
5.5L
10
steering gear
Z
4
suitable
11
bearing of the front尧rear hub
ZL
each 2
suitable
12
front bearing of transmission primary shaft
G
4
13
hinge of the door
G
14
lock of the door
G
2
15
power wiper
G
2
18
ground wire of the engine
H
4
suitable
16
rear axle
Z
4
1.75L
17
ground wire of the chassis wiring harness
H
4-2
suitable
79
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Table two: Description of the oil in lubricating table (for reference)
Symbol
in the table
J
H
Lubricant
L-ECC grade GB11122-89
industrial vaseline
G
GB491-87 2# lime base grease
ZL
GB5671-85 universal lithium base grease
B
half HV-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
80
HFC1020
series trucks
Number
1
12
Name
Nuts connected the transmission and the clutch housing
Fixing nuts of steering wheel
Tightening torque渊N窑m冤
80-110
54-68.6
2
Intermediate driveshaft flange nuts
46-62
3
Nuts of steering tie rod ball pin
98-127
4
Nuts of steering drop arm
196-250
5
Transmission flange nuts
180-220
6
Diving gear flange nuts
245-274.4
7
Nuts on the tyre
287-346
8
U-bolt of the front leaf spring
157-216
9
U-bolt of the rear leaf spring
157-216
10
Fixing nuts of the steering straight arm
316依35
11
Fixing nuts of steering flexural arm
316依35
Table three: Tightening torque of main fastening pieces (for reference)
81
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