JAC HFC1061 User manual

ThankyouforchoosingJAC.Wearepleasedtowelcomeyoutothegrowingnumberofdiscriminatingpeoplewhodrive
JACtruck.Theadvancedengineeringandhigh-qualityconstructionofeachJACwebuildissomethingofwhichweare
proud.
ThisOwner'sManualwillintroduceyoutothefeaturesandoperationofyournewvehicle.Ifissuggestedthatyoureadit
carefullysincetheinformationitcontainscancontributegreatlytothesatisfactionyoureceivefromyournewvehicle.
Themanufactureralsorecommendsthatallserviceandmaintenanceonyourvehiclebeperformedbyanauthorized
JACdealer.JACdealersarepreparedtoprovidehigh-qualityservice,maintenanceandanyotherassistancethatmay
berequired.
ANHUIJIANGHUAIAUTOMOBILECO.,LTD.
May.2008
FOREWORD

AllinformationinthisOwner'sManualiscurrentatthetimeofpublication.HoweverJACreservestherighttomake
changesatanytimesothatourpoliceofcontinualproductimprovementmaybecarriedout.
ThismanualappliestoallcurrentJACmodelsandincludesdescriptionandexplanationofoptionaswellasstandard
equipment.Asaresult,youmayfindmaterialinthismanualthatdoesnotapplytoyourspecificvehicle
I.Vehicle using 1
II. Engine21
III. Chassis29
IV.Electrical equipment63
V.Vehicle maintenance71
VI.Troubles shooting75
VII.Important information91
Contents
Page

1
Vehicleusing

Useofinstrumentsandap
paratusinthecab
Integrated switch and instru
mentcluster
Integrated switch (figure below),
whichiscomposedofsteeringshaft
lock seat ignition start lock and
combinationswitchliesunderneath
thesteeringwheel.
Ignitionswitch
Ignitionswitchisontherightsideof
integratedswitch.Ithasfourfunc鄄
tions:LOCK ACC ON START.When
thekeyisonthe'LOCK'position,
theignitionswitchhasbeenconnect鄄
edtothepowersourceandlockup
ofthesteeringgearhasbeendisen鄄
gaged.Turnthekeyto'ACC'posi鄄
tionclockwise,andcircuitofacces鄄
sorieslikeradioandtapeplayeris
connected.Turnthekeyto"ON'po鄄
sition,andtheinstrumentcircuitis
connected.Ifkeeponturningthekey
to'START'position,enginecanbe
started.Youshouldunlashhandleof
thekeyimmediatelyaftertheengine
starts.Thekeycanreturnto"ON'
positionbytheactionofspring.
Combinationswitch (leftcontrolhan
dle)
Combination switch is under the
controlofthemultifunctionalhandle,
whichliesinthelowerleftandinferi鄄
orplaceofthesteeringwheel.Itcan
controlsmall light headlight head鄄
lightdimmerandleftturningorright
turning by two different motion
modes.Thesymbolsandfunctionsof
integratedswitch
Ignitionswitch
2
Ignitionswitch
Integratedswitch
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thecombinationswitchareasfol鄄
lows:
"OFF"indicatesthatneithersmall
lightnorheadlightlights.
istheindicationofsmall
light.Turnthecontrolhandleclock鄄
wiseby30otolightenthefront rear
smalllightsandtheinstrumentlight.
istheindicationofhead鄄
light.Keeponturningtheleftcontrol
handleclockwiseby30otolighten
the front headlight the rear small
lightandtheinstrumentlight.
istheindicationofsteering.
Forwardandbackwardmotionofthe
controlhandlecanoperatetheleft
andtherightturninglightsandthe
turninglightindicatorontheinstru鄄
mentpanel.Pushthecontrolhandle
forwardinhorizontaldirection,the
rightturninglightlightsandthereis
indicationofturningrightonthein鄄
strumentpanel.Ontheotherhand,
pullthecontrolhandlebackwards,
theleftturninglightlightsandthere
isindicationofturningleftonthein鄄
strumentpanel.Ifthecontrolhandle
isinthemiddleposition,therewillbe
noindicationofturning.
Dimmerofheadlight:Lifttheleft
controlhandleupwardsgentlyand
dothe"uplift-release"motion,which
cancontrolthedimmerfunctionof
theheadlight.Ifupliftingthehandle
once,highbeamheadlightlights;if
releasingthehandle,itgoesout.Re鄄
peatingoftheaboveactioncancon鄄
troltheworkingconditionofthehigh
beamheadlighttoachievethepur鄄
poseofdimmerfunctionwhenover鄄
takingatnight.
Combination switch (right control
handle)
istheindicationofsyringe.
Whenthewashercontrolbuttonon
thetop of the control handle is
pressed,cleaningmixture(antifreeze
shouldbeusedinwinter)inthewin鄄
dowwasherwhichliesintheright
doorframeandunderneathinstru鄄
rightcontrolhandle
leftcontrolhandle
3

mentpanelcanbespoutedtothe
windshieldglassthroughthespout
underthewindow.
istheindicationofwiper.
Turningthecontrolhandleclockwise
inhorizontaldirectioncancontrolthe
wiper.Turnthecontrolhandleclock鄄
wiseby12otothe'LO'position,the
wiperworksatalowspeed.Keepon
turningclockwisebyanother12o,the
wipercanworkatahighspeed.
Whenthecontrolhandleisontheo鄄
riginalposition,thewiperwillbedis鄄
connectedorreturnautomatically.
istheindicationofexhaust
throttle assistant braking. Lift the
rightcontrolhandleupwardanddo
the'uplift-release'motion.Upliftthe
handle,theswitchcanbeconnected
andtheindicatorlightontheinstru鄄
mentpanellightswhichshowsthat
exhaust throttle assistant braking
works.Iftheacceleratorpedalorthe
clutchpedalisdepressed,theex鄄
haustassistantbrakingwillbecan鄄
celledautomaticallyandtheindicator
lightontheinstrumentpanelgoes
out.
Otherelectricapplianceswitches
Other electric appliance switches
mainlyincludehornbutton,danger
warningswitch,foglampswitchand
gatingceilinglightswitch.
1.Hornbuttonisinthecenterofthe
steeringwheel.Whenthebuttonis
pressed,itcanhoot.
2. istheindicationofdanger
warning switch. If the button is
pressed,thefront rear left right
turninglightsflashatthesametime
andsendoutemergencysignalfor
alarmindication.Ifpressedagain,
resetsignaloftheswitchisdiscon鄄
nected.
3. istheindicationofthefog
light.Pressthisbutton,thefoglight
lights.Pressitagain,theswitchre鄄
sets.
4. Ceiling light signal indicates
whetherthedoorofthevehicleis
shutcloselyornot.Ifonedoorkeeps
openornotshutclosely,theceiling
lightwilllighttoremindthedriver.
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5
DangeralarmandfoglampswitchOtherelectricapplianceswitch

Instrumentcluster
Newpatternofinstrumentcluster(airbrake)
Indicatorlamp Watertemper鄄
aturegauge
fuelgauge
Airpressure
gauge Mileometer SpeedometerTripmeter
Oldpatternofinstrumentcluster(airbrake)
Mileometer
Speedometer
Fuelgauge Indicatorlamp
Buttonforreturningtozero
Watertemperaturegauge
Tripmeter
Airpressuregauge
6
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Newpatternofinstrumentcluster(hydraulicbrake)
Oldpatternofinstrumentcluster(hydraulicbrake)
SpeedometerFuelgauge Indicatorlamp
Mileometer
Buttonforreturningtozero
Tripmeter
Watertemperaturegauge
Electricalclock
7

Indicators:
1.Turningindicationlight ( )
whentheturningcontrolhandleison
theleft (right)turningposition,left
(right)turningindicatorlightwillflash.
Ifthewarningswitchispressed,the
leftandrightturningindicationlight
willflashatthesametime.
2.Highbeamindicationlight( )
indicatesthatwhethertheheadlight
isundertheworkingconditionof
highbeam.Whentheheadlightis
on the high beam status, the
indicatorlightwilllight.
3.Fuelwarninglamp( ):usedfor
fuellevel alarm, whenfuel is in
shortage,fuelalarmlightwilllight.
4.Parkingbrakeindicatorlight渊冤院
whenpullinguptheparkingbrake
handle,theindicatorlightwilllight.
5.Generatorindicatorlight渊冤院in
dicates the working condition of
generator. When the battery is
discharged,theindicatorlightwilllight;
otherwise,theindicatorlightwillgoout.
6.Oilpressureindicatorlight渊冤院
indicateslow-pressurewarningof
engine oil pressure. When oil
pressureislowerthan0.08-0.1Mpa,
theoilpressureindicatorlightwill
light.Whenoilpressureishigher
thanit,theoilpressureindicatorlight
willgoout.
7.Brakingfaultindicatorlight渊冤院
whenbrakingfluidisnotenough,the
indicatorlightwilllight..
8.Exhaustassistantbrakeindicator
1.turnleft
2.highbeam
3.turright
4.fuelalarm
5.parkingbrake
6.charging
7.oilpressurealarm
8.brakingfault
9.exhaustassistantbrake
10.foglamp
11.smalllight
8
Integratedcluster
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light 渊冤院whenexhaustassistant
brakingoperates,theindicatorlight
will light. When exhaust assistant
brakeisdisconnected,theindicator
lightwillgoout.
9.Foglightindicationlight 渊冤院
presstheswitchtomakeitwork.
10.Smalllightindicati0nlight渊冤院
Whentheywork袁theindicationlight
willlight.
Useofcomponentsinthe
cab
Cab
Briefdescriptionofthestructure:
The driver cab is constructed
enclosingwithfullmetal.Window
glass adopts panoramic camber
windshield.Inordertoimprovethe
comfort, side panel with larger
upsidewidthandraised-roofcab
havebeenadopted.Therefore,the
interiorspaceofthecabcanbe
morecommodiousandcomfortable.
Effectivemeasures havetaken in
reducing noise heat insulation
soundinsulationandsealing.For
instance,thesectionofroofforehead
isenclosedandstrengtheningribis
equippedontheroof.There are
three asbestos heat insulating
mattressontheupsideoftheengine.
Sealingofthedoorisdoubleskin
constructed. For safety, softening
hasdoneforthemainparts,which
can appear knocking easily with
passengers.
Air-conditionersystem(choose
topack)
Briefintroduction
Theautomobileair-conditionerwith
coldandwarmmachineisintegrated
withautomobileclusterpanel.Ithas
manyusefulfunctions.Forexample,
tomakecoldair,warmairandto
removefrost.The air-conditioner
system has four high and low
grades,whichmeetsyourneedof
9

choosing different air speed and
directionofairsending.
Operation
1.Starttheengine.
2.PressSwitch4oftheaircondi-
tionertostartairsender.Theswitch
hasfourgradesfromlefttorightto
maketheairspeedmoreandmore
quickaswellasmakingairstronger
andstronger.
3.Operateair-conditionerSwitch5,
thenthecompressorbeginstowork
andthewholesystemworkstoo.
4.Whenusingcoldwind,pleaseput
theTemperatureadjustinghandle3
totheCOOLposition.Whenusing
warm wind, put it to the HOT
position.Tohaveairsendingfrom
different directions, please adjust
Handle2.Tousewarmwindonly,
pleasecloseSwitch5oftheair-
conditioner.
5.OperateHandle1onnaturalwind
conversionpositiontohavenatural
windoutsidecomeintothecab.
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Caution!
1.Avoidputtingthehandletothe
coldestpositionandpressingthe
airspeedswitchonthelowest
position when using the air-
conditionerinorder toprevent
evaporativemachinefromfrosting.
2.Donotparkthevehicleunder
thesun.
3.Closethedoorandwindowsof
cabwhenusingair-conditioner.
4.Usecompressedairandcold
watertowashthecondenser.(hot
waterandsteamareforbidden)
5.Havethecompressorworked
for5minutesonceaweekin
wintertomaintaintheaircondi-
tionerworknormally.
6.Makesurethetemperatureof
waterusedtocoldtheenginereach
to70益abovewhenusingairheater
andyoushoulduseantifreezefluid
toavoidfreezingradiatorandinside
ofairheatertobecracked.
7.Ifyoudonotunderstandthe
structureandhavenomeasuresof
Thetopofcab'sventilatingdevice
You can choose two ways to
ventilatethecab.Outdoorairiness
andindoorairiness
Outdoorairiness
1.Clockwisetherotary-knobonthe
topofcabtomakesurethetopcab
closed.
2.Turnontheswitchto"IN",then
turnontherotaryknobto"OPEN".
Indoorairiness
1.Clockwisetherotaryknobtoclose
theventilatorlouver.
2.Turntheswitchto"out"whichison
theexhaustgear.
Door
1.Thecabdoor,whichhasthree-
step opening, can improve the
convenienceforpassengerstoget
onortogetoff.Thepartialopening
anglecanbe30益and57益.And
thefullopeninganglecanbe90益,
onallofthethreepositions,thedoor
canbeinstablecondition.(figure
above)
Outsidedoorhandle(left) Lockof
doorlocking(right)
Pullouttheoutsidedoorhandleto
openthedoor.Insertthestarting
switchkeyintothedoorlockand
11
protection,pleasedonotswitch
onthesystemofairconditionerto
avoidaccidents

rotateittolockthedoor.
2.Thedoorcanbelockedoutside
withoutthekey.Firstpressthelock
buttonontheinnersideofthedoors
tothefixedposition,thenpullthe
outsidedoorhandleoutwardsand
closethedooratthesametime.
3.Pullouttheinsidedoorhandleto
openthedoor.
4.Pressthelockbuttontolockthe
doorafterclosingit.
Cabseat
Cabseatcanbeclassifiedasdriver
seat,assistantdriverseatandrear
rowseat.Driverbackseatadopts
uprightseat.Theangleofbackrest
andthefore-and-aftpositionofseat
can be adjusted. The maximum
adjustableangleofthebackrestis
56益.Themaximumadjustabledist-
anceoftheseatis160mm. Whenvehicleisintheprogressof maintenance,pleasecleanthetrack
assemblyofthedriverseat,recoat
thelithiumbasegrease,andtighten
allofthejointnutsagain.Iffinding
theslidingtrackshakingorblocking,
itshouldberepairedorbereplaced
withcomponents.
Cabtiltlockmechanism
cabtiltlockingdevice
12
1.chuckrod
2.overturnrod
3.safelocking
hook
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Briefintroductionofthestructure:
Thecabhasturnoverfunctionswith
turnover and lockup system.
Turnover system is composed of
torsionbar,supporting-axle,cab's
rearbracketandsoon.Thecabto
turnoverisusedbytorsionpower.
Lockupsystemiscomposedofright/
leftlockunit,turnoverlockunit,short
pullrod,longpullrod,rearbracket
ofcabandsoon.Alloftheseareto
lockthecabtootightlyandtomake
surethevehicleturnoverautomati-
callywhendrivinginanysituation.
Pleasereadthetiltingnotesonthe
leftdoorofthecabandontheupper
flangeofthewheelseriouslybefore
tiltingthecab.Thenotesareshown
inthefigureabove.
Useandmaintenance
Inordertotiltthecabandrunthe
vehiclesafely,pleasepayattention
tothefollowingcontents.
Cab tilting method and relative
notices.
1.Whenstoppingthevehicleonthe
horizontalroad,youshouldmake
sure that thereis enoughspace
aroundthecabbeforetilting.Orelse,
thecabmaybedamaged while
tilting.
2.Pulluptheparkingbrake,push
the shifting rod into the neutral
positiontoavoidtheself-slidingof
thevehicle.
3.Thecabdoormustbefastened
up.Youshouldtakeawayallthe
goodsontheinstrumentpanel seat
andfloortoavoidthedamageofthe
doorandthefrontwindshield.
4.Disengagedthelockingfunctionof
thecablockingmechanismatfirst
whentiltingthecab.
5.Afterthelockingfunctiondiseng-
aged,holdthetiltingrodwithhand
andpullupthesafetylockhookat
thesametimetoavoidthesudden
upliftofthecab.
6.Raisethecabslowlyuntilittiltsto
the highest position, then lock it
carefullywithlockarmontherear
bracket.
7.Whenloweringthecabdown,first,
holdthetiltingrodanddisengage
13
Notice

thelockingfunctionoflockarmon
therearbracket,thenlowerthecab
downslowly.Afterthesafetylockbe
locked,fastenthelockingmech-
anism.
Inspectionandmaintenance
1.Checkperiodicallytherubberpad
assemblies which are used to
strengthenthefront rearsupport,if
found damaged, it should be
replacedinstantly.
2. Check periodically the locking
situationofthelockingmechanism,if
foundnotwork,itshouldberepaired
orreplacedimmediately.
3.Ifitisdifficulttotiltupthecaband
putitdown,thetorsionrodcannot
work.Replacethetorsionrod.
4.Whenrepairingthechassis,before
removingthecab,disengagethe
forceofthetorsionrodandoperate
withthefollowingsteps.
Disengagethelockingstate,and
tiltupthecabtothehighestposition.
Removetheshaftpinconnected
the rear support rod and the
baseboardsupportofthecab.
Pushthecabforwardtosome
angleuntiltheboltonthetorsionrod
armcanbeloosened.
Aftertheboltremoved,thetorsion
rodcannotwork.Nowthecabcan
beremoved(Thetorsionrodcannot
bepulledout).
5.Beforerevertingthecabtothe
originalposition,returntheforceof
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Note: Thementionedabovework
mustbedonebythreepersons
atleastbecausetwoorthree
personscannotpushthecab
forwardaftertheforceofthe
torsionroddisengaged.
thetorsionrodandoperatewiththe
followingsteps:
Putthetoothpartofthespline
whichiscutatthebottomononeend
ofthetorsionrodinalignmentwith"1"
positiononthesupportaxletubeand
thesplinetube,andinsertthetorsion
rodintothesupportaxletube(forthe
rodwhichispulledout).
After mounting the cab with
supportaxletubeandtheleft right
brackettogethertotheframe,putthe
"1"ofhubsplinesonthetorsionrod
inalignmentwiththesplinetooth
whichiscutatthebottomonthe
otherendofthetorsionrod,cover
thehubsplinesonthetorsionrod
andinsertthesplineaxletubeinto
therightbracketinthecab.
Tiltthecabforwarduntilthebolt
holeonthetorsionrodarmaimedat
thescrewedholeontherightbracket
inthecab,screwtheboltandtighteni.
Putthecabdownslowly,and
checkwhetherthecabisonthe
stateofsuspendinginthehorizontal
directionafterdroppeddown.Ifit
worksnormally,lockthecab.
6.Iffindingthetorsionrodnotwork,
referringto(4)(5)whenreplacingit.
Startingandrunningofthe
vehicle
Startingofthevehicle
Startingoftheengine
Aftermakingpreparationsforstarting
engine,first,puttheshiftbaronthe
neutralposition,turnontheignition
switch,thencheckhorns instruments
on the instrument panel turning
lamps brakinglamps theangleand
positionoftherearviewmirror.
1.Routinestart
TurnthekeytotheSTARTposition(As
shownontherightfigure),theengine
canstart.Afterstarting,loosenthe
acceleratorpedalimmediatelyand
keeptheengineworkinginlowspeed.
Pressing the accelerator pedal
15

violentlyisforbidden.
2.Startinwinter
Whenitisverycold,referringtothe
followingmeasurestostartengine.
Usehotwatertotaketheplaceof
coolingwater,turnonthedrainage
switchwhenheatingthewater.When
thehotwaterflowoutandtheengine
body become warm, close the
drainageswitch.
Heatuptheoilupto80益耀90益,
andthenadditintotheoilpan.
Afterstartingtheengine,checkthe
operatingstateoftheengineand
instruments at different rotating
speed. Especially check the oil
pressure.Check whetherthereis
leakage of water oil and gas,
whethertheoillevelisnormaland
whetherthereisnoisecomingfrom
the engine as well as checking
whether the color of exhaust is
normal.
3.Afterstartingtheengine,donot
presstheacceleratorpedalviolently,
loosentheacceleratorpedaltokeep
theengineoperatingonidleforsome
time.Afterthetemperatureofengine
rising and the engine operates
stably,uplifttheclutchpedalslowly.
4.Usuallyrunthevehicleafterthe
temperatureofenginerisingto60益
andtheoperating (sound)ofthe
engine and the reading of
instrumentsarenormal.Donotrun
thevehicleinlowtemperatureto
avoidwearingtheengine.
Startingandshiftingofthevehicle
Afterengineoperatesnormally,press
theclutchpedal,shiftintolowgear,
loosentheparkingbrake,andpress
thehornonce.Makesurethatthe
vehicle can be operated safely,
loosentheclutchpedalslowlyand
depress the accelerator pedal
properlyatthesametimetostartthe
vehicle.Afterstartingthevehicle,the
footshouldbewentawayfromthe
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17
clutchpedal.Donotkeepthefooton
thepedaltoavoidtheburningoutof
theclutchfrictiondisc.
Whenshifting,donotjustseethe
shifting rod .You should watch
forwardandholdthesteeringwheel
steadilywithyourlefthand,having
thehollowofthepalmofyourright
handsticktothetopoftheshifting
rodandpushorpullittotheright
positionwithyourrightwrist.
Running,swerving,turnaround,bac-
kingandbrakingofthevehicle
1.Running:
Keep enough distance to the
foregoingvehiclewhenrunningon
flat road. Select vehicle speed
according to the vehicle model,
missionandconcreteconditionof
road,generallyselectthespeedof
50-70km/h.
Letthevehicleruninthefirstor
second gear when starting,
upgradingunderheavy load and
runningonbumpyroadoronthe
roadwithobstacles.Butthevehicle
cannotberuninthefirstorsecond
geartoolong.Whenupgradingwith
heavyload,shifttheshiftingrodinto
lowgeartoavoidoverloadingofthe
Note: Donotletthevehiclerunin
thefirstorthesecondgearfora
longtimetopreventfromincreasing
the wearing and the fuel
consumption. Loosen the clutch
pedal rapidly or depress the
acceleratorpedalinsufficiently,the
enginecanstop.
Whenrunningthevehicle,shiftthe
gearaccordingtothechangeof
roadandlandform.Iffindingthe
enginepowerabundantandthe
rotatingspeedrises,itillustrates
that the primary gear is not
appropriate,thevehicleshouldbe
shiftedtothenextfastgearintime.
Aftershifting,ifnotfindingshortage
ofpowerand chatteringoftrans-
mission,theshiftingoperationcan
beconsideredright.Forsafety,
whenswerving,passingbridge
andmeeting,thevehiclecanrun
inmoderatespeed.Iftherunning
conditionisbetter,thevehiclecan
runinhighspeedsoastomake
thespeedhigherandeconomize
thefuel.

18
engine.
Whenrunning,donotincreaseor
decreasethevehiclespeedabruptly
anddonotshakethesteeringwheel
withoutreason,listenwhetherthereis
abnormalnoiseornot,checkthe
readingandindicatorlampofallthe
instruments for normalization. If
findingabnormalnoiseorabnormal
events,stopthevehicleimmediately
and check it, take necessary
adjustmentandrepair.
Whendowngrading,donotstallthe
engine. When downgrading steep
ramp,shifttheshiftingrodintolow
gearandtakebrakingoperationat
intervalstoavoidtheoverspeeding
running
Whenrunningacrossashallowriver
orloblolly,preventthewaterfrom
enteringintoairintakelinesofthe
engine,rearaxlesandtransmission
case.Checkrearaxleandtrans-
missioncaseforenteringwaterafter
padding.Ifthereiswater,drainoffit
andaddspecifiedquantityofgear
oil.Thevehicleshouldnotrunata
high speed after padding, brake
pedal should be depressed at
intervals to resume the braking
performanceassoonaspossible.
Whenrunningonicyorsnowyroad,
runatsteadyspeed.Donottake
emergencybrakinganddonotturn
thesteeringwheelfiercelytoavoid
skiddingdanger.Keeplongsafety
distancefromtheforegoingvehicle.
Whenrunninginheavyrain,drivethe
vehicle more carefully to avoid
decreasingthebrakingperformance
ofthebrakebecauseofmoist.Do
nottakeemergencybrakingopera-
tiontoavoidthedangerofskidding.
2.Swerving
Swervingofthevehicleproduces
centrifugalforcewhichcanbebigger
whenthevehiclespeedbecomes
higher.Theforcecanbringturning
overinthetransversedirectionin
seriouscondition. Therefore,inthe
50-100 meters position before
swerving,youshouldringthehorn,
turnontheturninglampandreduce
onthefreezingandmuddyroadorin
theweatherofheavyrain,fog,wind,
sandandreducethevehiclespeed
to less than 10km/h, swerve the
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19
vehicle solely alongside the right
sideofroad.Whenswerving,turnthe
steeringwheeluniformlyaccordingto
thesituationofroad,theswerving
trackshouldbetransitedsmoothly,
theturningmotionshouldnotbetoo
greatortoosmall.Donotturnor
returnthesteeringwheelsuddenly.
Tryyourbesttoavoidtakingbraking
operationwhileturningthesteering
wheel,especiallyemergencybraking.
Whensteering,iffoundskiddingof
the front wheels, put up the
accelerator pedal and turn the
steeringwheelproperlyalongthe
skiddingdirection,andcorrectthe
runningdirectionaftertheskidding
stops.
3.Turningaround院
Whenturningthevehiclearoundby
180益,selectthesquare,large-
scalecrossingorflatbroadwhich
havelittletrafficfluxandturnaround
the vehicle at a time along the
runningdirection.Atthe50-100
meterspositioninfrontoftheturning
spot,reducethevehiclespeed,shift
intolowgearandsendoutturning
aroundsignal.
Whenturningaroundwithrunning
forwardsandbackwards,sendouta
turningaroundsignalatfirst,reduce
thevehiclespeedandruntowards
the right side of road . When
approaching the preset spot for
turningaround,observethesituation
ofroad,turnthesteeringwheeltothe
left extreme position rapidly and
havethevehicleruntotheleftside
ofroadslowly.Whenapproaching
the roadside, return the steering
wheelrapidly.Afterobservingthe
situationbehindthevehicle,start
andturnaroundvehicle,turnthe
steeringwheeltotherightextreme
positionatthesametime.When
approachingtheroadside,returnthe
steeringwheelrapidlyandstopthe
vehicle. If the turning around
operationcannotbedoneforonce,
repeattheoperationsabove.
4.Backing 院
Theoperationofshiftingintoreverse
gearorshiftingfromreversegearto
onwardgearcanbedoneafterthe
vehicle stopped completely. After
shiftingintothereversegear,the

20
back-uplightlights.Thevehicle
speedmustbelessthan5km/h
whenbacking.Ifthedrivercannot
discern the situation behind the
vehicle because the vehicle is
loadingorbecauseofotherreasons,
the backing operation must be
commandedbyonepersonwhois
notinthevehicle.Donotbackthe
vehiclewithoutcommanding.
5.Parkingofthevehicleandstopof
theengine.
Whenpreparingtoparkthevehicle,
thevehiclespeedreducesorthe
vehicle slides out of gear and
indicateswithturninglight.Afterthe
vehicleparked.Pulluptheparking
brakerod.Ifthevehiclemustbe
parked on the road for some
reasons,parkthevehiclenearthe
roadsideanddonotparkthevehicle
on the running lane. Under the
exceptionalconditionlikebreaking
downinthemiddleofroad,two
cautionplatesshouldbeplacedon
thepositionof200metersinfrontof
andbehindthevehicle.
Avoidparkingontheramp.Ifthe
vehiclemustbeparkedontheramp,
pulluptheparkingbrakerodtothe
extremeposition,shiftintolowgear
andblockthevehiclewithtriangular
chocksorstonestopreventitfrom
sliding.Note:Makesurethatthe
parking brake can work when
parkingontherampatthesame
time,turnontheemergencywarning
signalindicatorlight.
Afterparking,especially afterthe
engineoperateswithheavyload,do
notstalltheengineimmediately,and
keeptheengineoperatinginlow
speedforseveralminutes.Afterthe
temperatureofwaterdecreasesto
lessthan70益,vehicleisgoingto
stop.
Whenparkingmidwayinwinter,take
theheatpreservationandantifreez鄄
ingmeasuresfortheengine.Prevent
theoiltankfromisolationinsummer.
Afterthevehicleruns,routineservice
andinspectionshouldbedoneon
theentirevehicle噎噎
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Engine

Airinletandairexhaust
systems
Inletsystemincludesairinletpipe
assembly airfilter branchpipeof
airinlet.Airexhaustsystemincludes
exhaustpipe mufflerandexhaust
tailpipeetc.
Usingandmaintenance
1.Servicelifeofenginehastheclos鄄
estrelationship with the working
conditionofairfilter.Itisforbiddento
usetheenginewithoutairfilteror
withairfilterthatcannotwork.Taking
theairinletportofairfilterastheini鄄
tialairinletportisalsoforbidden.
2.Checktheinletmanifoldandex鄄
haustmanifoldforevery1000kmrun鄄
ning.
Checknutsforlooseness,when
tighteningthenutontheinletand
exhaustmanifold,thetorsionforce
shouldbeequable,orelsetheair
leakagecanoccur.
Checktheinletandexhaustmani鄄
foldforcrackandhole,checkthe
gasketfordamageanderosion,if
findingthosephenomena,replaceit
withanewone.
Airfilter
Thefunctionofairfilteristofiltrate
outthedustandthesandintheair
enteringintotheengine.
Airfilteriscyclonedustgatheringair
cleanerwithpaperfilterelement.Af鄄
terexternalairenteringintotheairfil鄄
terthroughtheairenteringintothe
airfilterthroughtheairinletpipe,
22
Thesignboardofengine
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Note院The details of the engine
structure assembling adjust鄄
ment usingandmaintenancecan
be consulted in the operating
specificationofrelevantengines.
Note: thereisasignboardofen鄄
gineonthetoporonthesideof
thecylinder.Markedwithmodelof
engine,serialnumberwhenleav鄄
ingthefactory,datewhenleaving
thefactory,demarcatedrotational
speedetc.pleasefindtheexact
positionsoastouseandrepairour
product.
23
largerdustparticlecanbeseparated
fromtheairbythefunctionofcy鄄
clonevane,thencanbethrowninto
thedustgatheringplate,thesepa鄄
ratedairkeeponmovingandenter
intothecylinderbythefilteringfunc鄄
tionofthepaperelement.
Forevery1000kmrunning,check
andmaintaintheairfilter.Whenrun鄄
ningintheconditionofexcessive
dust,therunningmileageintervalfor
inspectionandmaintenanceshould
beshortenedsuitably.
Cleaningoftheaircleaner:
1.Removethedishshapednutfrom
thecoveringlid.Getthefilterelement
afteropeningthecoveringlid.
2.Cleanthecoveringlidandinside
oftheoutercoveringwithcleanand
drycloth.Whencleaning,donotlet
thewaterenterintothefilterelement.
3.Cleanthedustunloadingvalveto
makesureitisn'twornandcan
work.
4.Checkwhethertherubbertube
connectedtobrakeistightornot
andcloseittightly.
5.Cleanthefilterelementofthefilter.
Usecompressedairguntoremove
thedrydirtordust (airpressure
shouldbelessthan690kpa),remem鄄
bertoblowfrominnersidetoouter
sideofthefilterelementtoclear
awaythedirtordust.Pattingor
knockingareforbidden.
Coolingsystem
Briefdescriptionofthestructure
Coolingsystemadoptsclosedwa鄄
ter-coolingpressurecycletype.Itis
composedofradiator coolingfluid
thermostat fangear connectionhose
etc.
Maintenanceofcoolingsystem
1.It'srecommendedtouselong-
termeffectiveantifreezepreservative
liquidofglycolbaseascoolingfluid.
Inthenorth,itcanavoiddamageto
theengineduetosolidificationof
coolingfluidinwinter;inthesouth,it
canincreasetheboilingpointof
coolingfluidinsummertoavoid
damagetoengineduetoairresis鄄
tanceinhightemperature.
2.Everytimebeforedriving,check

24
theliquidlevelintheradiator,ifthe
liquidisfoundinsufficient,itshould
beaddedtospecifiedlevel.
3.Drainageofcoolingsystem.In
coldregionandinwinter,forlong-
timeparkingorfinishingusingthe
vehicleeverydaywithoutusinganti-
freezingpreservativeliquid,thecool鄄
ingsystemmustbedrainedandthe
waterfillercapoftheradiatormust
beopenedtoavoidtheincomplete
drainageofcoolingwater.
4.Afterengineoperatingforalong
time,furringcanbeproducedinthe
cooling water and it should be
cleanedintime.Cleanitwiththefol鄄
lowingmethod:mix700-800gram
kerosene,addthemixtureliquidinto
thecoolingwater,runinmedium
speedfor5-10minutes,thenafter
enginestopworkingfor10-12hours,
restarttheengineandrunfor10-15
minutes.Thendrainthecoolingsys鄄
temwithcleanedwater.
Itemsinusinglong-termeffectivean
ti-freezingpreservativeliquid
1.Choosesuitableantifreezeaccord鄄
ingtothelowesttemperatureofthe
region,ifthelowesttemperatureof
theregionis-25益,antifreezeof
which solidifying point is -30益
shouldbechosen.
2.Anti-freezingpreservativeliquidof
thesametypeshouldbeusedin
addingincaseofdeposition.
3.Iffindingdeteriorationoftheanti-
freezingpreservativeliquid,replace
itentirelyatonce.Normalcolorofthe
anti-freezingliquidisgreenorblue,
iftheliquidisdeteriorated,thecolor
willbecomedeepredbecauseofin鄄
filtrationofimpurity.
Adjustingoftensiondegreeoffanbelt
pulley
1.Tootightortooloosefanbeltdoes
nogoodtooperatetheengine.
Consultengineassemblyfordetails
ofadjustingmethods.
2.Adjustingmethods:Adjustthefan
beltwithadjustingboltsfirst,thendo
accurateadjustingwiththetension
rod;adjustdegreeoftensionofthe
V-beltwithfingers,presseachbelt
with98Nforce.Lengthofcrankshaft
beltpulley-belttensionpulleyis10-
15mmandlengthofbelttensionpul鄄
ley-fanbeltpulleyis7-8mm.
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Briefdescriptionofthestructure:
Acceleratingtransmissiondeviceis
composed of accelerator pedal
mechanism acceleratordrawingwire
andspeedgovernorhandleoftheen鄄
gine.(Asshowninthefigureabove)
Whenpressingthepedal,driving
deviceofthemechanismpullsthe
drawingwireandcontrolstheopen鄄
ingextentoftheacceleratortoin鄄
creaseordecreasethespeed
1.Acceleratorpedalmechanism:
Thismechanismadoptsthelatest
structureofISUZUtruck.Itoperates
simplyandsafelyandisconnected
totheacceleratingdrawingwireand
thehandthrottledrawingwire;struc鄄
tureofthepedaladoptsinjected
moldingtype,whichmakestheas鄄
semblyconvenientandcauseslittle
operatingnoise.
2.Acceleratingwiredrawing:
Itisoperatedwithsoftdrawingwire
andhasasafestructure;it'schar鄄
acterizedwithconvenientlayout lit鄄
tlefrictional resistance and stable
transmission.
Handthrottle
1.Brakingpedalbracket
2.Manualthrottledrawingwire
3.Acceleratordrawingwire
4.Acceleratorassembly
5.Acceleratorpedalassembly
6.Accelerationoscillatingarm
oftheengine
7.Frame
Schematicdiagramofacceleratingtransmissiondevice
Acceleratingtransmissionsystem

26
3Manualthrottledrawingwire:
Usingwiththefootthrottlecanquick鄄
enthepreheatingoftheengineorin鄄
creasetheidlingspeed.
Usingandadjustment
1.Checkthechuckingpositionofthe
linkage rod and the accelerator
mechanismforrightnessandreliabil鄄
ity,checkthedirectionofthewire
drawingforstraightandcheckon
thecorneringforsmoothtransition.
2.Thepedalshouldbedepressed
easilyandtotheextremeposition
withoutjamming.Whenreleased,it
shouldreturnfreely.
3.Whenpressingthepedal,ifthe
freeplayistoolargeortheopening
degreeoftheacceleratorisinsuffi鄄
cient,adjustthepositionofbolts.
Fuelsupplysystem
Briefdescriptionofthestructure:
Fuelsupplysystemiscomposedof
fueltank fuelfilter fuelpump fuel
injectionpump fuelinletpipeand
fuelreturnpipe.
Thefunctionofthefuelsupplysys鄄
temistoinjectspecifiedquantityof
dieselwellatomizedintothecylinder
regularlywithdefiniteintervalofin鄄
jectionandunderdefinitepressure
accordingtoengine-operatingre鄄
quirementaswellasmakingthe
dieselmix withtheair well and
rapidly.Operatingstateoffuelsup鄄
plysystemhasgreatinfluenceon
powerandeconomicperformanceof
theengine.
Rough filter: fuel supply pipe is
mountedwithDX15OTtypespin-on
precipitator.Itsflowvolumeis1.5L/
min.Itcanfilterbigforeignparticles
andcanseparateoilfromwater.
Fueltank: oilfillerismountedwithfil鄄
teringscreensoastopreventbig
foreignparticlesfromenteringintofu鄄
eltank.Thelowestpositionofbottom
offueltankismountedwithoilboltto
clearthedepositandwateraway.
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Usingandmaintenanceofroughfil
ter:
1.Checkthechuckingpositionof
pipelineinterfaceforsealing,reliabil鄄
ityandairleakage.
2.CheckDX150Ttypeprecipitator
forwater-proofingmaintenancefor
every1000kmor200hs'working.It's
unnecessarytochangethefilterele鄄
ment.

Chassis
29

Clutch
Briefdescriptionofthestructure:
Theclutchequippedforthisseries
truckissingle-platedrytypedi鄄
aphragmspringclutch.Clutchfacing
iscomposedoftwofrictiondiscsand
clutch facing riveted with rivet.
Clutchpressureplatepressesfriction
discsonpillarbyusingpressure
producedbydiaphragmspringto
producejointingforce.
Adjustmentoftheclutchoperating
system:
1.Adjustthelimitscrewoftheclutch
pedaltomakesurethatthefreeplay
ofthepedalis3耀5mm.
2.Adjustthemastercylinderofthe
clutch:Loosenthelocknutonthe
pushrodofthemastercylinder,ro鄄
tatetheendofthepushrodtocon鄄
tactgentlywithpistonofthemaster
cylinder,thenrotatethepushrodfor
3/4circleinthecontrarydirection,
tightenthelocknutofthepushrod,
andtheclearance
betweenthepushrodandthepiston
isabout0.5耀1mm.
3.Adjusttheclutchreleasepump:
rotatetheadjustingnutonpump's
pushrodandhavetheclutchrelease
fingertouchtheclutchreleasebear鄄
ing.Thenrotateadjustingnutinthe
contrarydirectionandmakethefree
playofclutchreleaseforkreachto
2-3mm.Tightenthenutatlast.Part
of the vehicle model use clutch
booster.Adjustthefreeplayofthe
rockerarmendonclutchreleasefork
to3-5mm
4.Bleedairfromwheelcylinderof
theclutch
Airoroilleakageinthehydraulic
pipelineoftheclutchisnotallowed,
orelse,itcanresultinthedisability
ofthepedal,deficiencyoftheeffec鄄
tivetravelandincompletereleaseof
theclutchetc., whichmakethe
clutchnotworknormally.Theworkof
airbleedingshouldbecompletedby
twopersons.Onepersonpresses
the clutch pedal and the other
bleedstheair.
30
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Takeofftherubbercapoftheair
bleedscrewonthewheelcylinder,
linkaplasticpipeontheairbleed
screw,puttheotherendofthepipe
intothecontainerfilledwithbrake
fluid,presstheclutchpedalforsev鄄
eraltimes,fillthemastercylinderand
hydraulicpipelinewithbrakefluid,
thenloosentheairbleedscrew.Air
bubblecanbepuffedfromtheoil
ringifthereisairinthepipeline.Be鄄
forethepedalreaches thefloor,
tightentheairbleedscrew.Repeat
theoperationmentionedaboveuntil
thereisnoairbubblereleasing.
Maintenanceandadjustmentofclutch
Longtimeuseorincorrectadjust鄄
mentandincompleteairbleedingof
theclutchcancauseincompletere鄄
leaseoftheclutchandmakethe
clutchinhalfcontactstateforalong
time,whichaggravatewearingofthe
clutchpressureplateandfrictionlin鄄
ings.Decrepitating,burningandex鄄
foliationofthefrictionlining,and
burnoutofthereleasebearingcan
evenresultintheabnormaloperation
oftheclutch.Whendoingmainte鄄
nance,allkindsofclearancesofthe
clutchmustbeadjusted.Whendoing
class-threemaintenance,cleanthe
masterpumpanddistributorpump
andliquidreservoirtank,fillingthe
newlubricationintotheinsideofre鄄
leasebearing.
1.releasefork 2.dustcover
3.copperwasher 4.releasecylinder
5.wrench 6.softplasticpipe
7.container 8.braking

Transmission
Transmissions equipped for the
chassisofthisseriesoftruckare
LC5T97,LC5T30,LC6T46.Among
these,LC5T97andLC5T30areman鄄
ualfixedaxlewithstages.Thereare
fiveforwardgearsandoneback
gear.Thesecond,third,fourthand
fifthgearhassynchronizerthatis
synchromesh. The first and back
gearareconstantmesh.Transmis鄄
sionusessynchronizertomakegear
shiftingconvenient.Itcanreduce
wearandtearoftoothandshock,
prolongthelifeofgearlinkage,short鄄
enthetimeofgearshifting,improve
theaveragevehicleandreducelabor
intensityetc.
Gear shifting of transmission is
workedbytransmissiongearshifting
control mechanism, controlled by
long-distancesoftshaftandrod.
Shiftingcontroldeviceoftransmis
sion.
Shiftingcontroldeviceoftransmis鄄
sioniscontrolledbylong-distance
softhigh-floorshortrod,usingtwo
flexibleshaftstochooseandshift
gear.Itiscomposedbycontrolbar
baseassemblyandgearselecting/
shiftingandpropstand.Theinner
coreshaftofflexibleshaftissteel
wirerope.Gearselecting/shiftingis
accomplishedbysteerwirerope's
pullingandpushingmotion.Theball
ontheflexibleshaftandadjusting
screwareusedforadjustingthetotal
lengthoftheflexibleshafttoensure
thegearselecting/shiftingcanbe
completed.Therearemarksofthe
transmission,whichisshowninthe
figurebelow.
Controlhandleoftransmission
Schematicdiagramofthetransmis鄄
siongearshiftcontroldevice
32
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Usingandmaintenance:
1.Iffindingthegearshiftingcannot
operateoroperatesdifficultlywhen
theengineisnotworking,itshows
thatthegearshiftingrod(ortheflex鄄
ibleshaft)hasmaladjustmentorthe
boltbecomesloose,nowyoumust
adjustthecontrolrod (ortheflexible
shaft),checkandtighteneverybolt
andeverynut.
2.Iffindingout-of-gearwhenrun鄄
ningontheroughroad,thecontrol
rod(ortheflexibleshaft)hasmalad鄄
justment,anditshouldbeadjusted
correctly.
3.Iffindingfreeplayofthecontrol
rodistoolarge,checkandtighten
everyboltandeverynut.
4.Donottakegearshiftingoperation
33
1.gearshiftcontrolrod
2.dustcover
3.handle
4.floorofthecab
5.flexibleshaftforgearselecting
6.transmissionrockerarmforgearselecting
7.sidebracketforgearshifting
8.flexibleshaftforgearshifting
9.fixedbracketofthegearshiftingflexible
shaft
10.rearcoveroftheclutch
11.transmissionrockerarmforgearshifting

whentheengineworksatanover
fastspeedtoavoidacceleratingthe
wearofthesynchronizer.
5.Whenshifting,theforceshouldbe
gentle.Thehandforcemustbeact鄄
edonthecontrolroduntilthegear
reachesthecorrectposition.Shifting
withflapofpushandlooseningisin鄄
appropriateandtheshiftingopera鄄
tioncannotbeaccomplishedeasily
inthisway.
6.Youcanshiftfromforwardgearto
reversegearorfromreversegearto
forwardgearonlyafterthevehicle
stopsstably,orelse,thegearcanbe
damaged.
7.Thefifthgearisover-speedgear,
itcanbeusedwhenthevehicle
speedisover50km/htoavoiddam鄄
ageoftheover-speedgearresulting
fromoverloading.
8.Duringdriving,ifthereisanyab鄄
normal noise in the transmission,
stopthevehicleandcheckittoelimi鄄
natethemalfunction.
9.Whenslidingonthedowngrade,
stallingoftheengineisnotallowed;
startingtheenginewiththeinertiaof
slidingonthedowngradeisforbid鄄
denincaseofdamageofthegear
andthesynchronizer.
10.Duringbreaking-inperiodofthe
new vehicle, because the metal
chippingwhichisproducedbythe
frictionalfunctionbetweennewparts
doesharmtocomponentsinthe
transmission,especiallytothedura鄄
bilityoftheconicalringsofthesyn鄄
chronizer, so the lubricating oil
shouldbereplacedafterthebreak鄄
ing-inperiodofthenewvehicleex鄄
pires.Undergeneralcondition,re鄄
placethelubricatingoilonceforev鄄
ery6000kmrunning.Whenreplac鄄
ingthelubricatingoil,firstdrainoff
theoilinthetransmission,propup
therearaxle,shiftthetransmission
intothereversegear,addkerosene,
keepthetransmissionrotatingfor2耀
3minutes,thendrainoffkerosene,
addpuregearoil.
11.Checktheoillevelinthetrans鄄
missionfrequently,iftheoillevelis
undertheloweredgesurfaceofthe
oilfillerbolthole,sufficientoilshould
beadded.
12.Checktheoutsideboltofthe
34
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transmissionandtheflangeofthe
second shaft for tightening and
workingconditionofthecomponents
inthetransmissionfrequently.Be鄄
causetheventplugiseasytoblock
bydust,whichcausesincreasing
pressure in the transmission, oil
seepageorleakage,sotheventplug
shouldbecleanedperiodically.
13.Themovementpartofshifting
operationcomponentshouldbelu鄄
bricatedwell,orelse,itwillbehard
toshiftbecauseofthewearingofthe
movementparts.Ifthepositionof
gearselectingisfoundincorrectly,or
gearshiftingisdifficultorthetrans鄄
missionisoutofgearautomatically
inusing,firstlyyoushouldreadjust
thegearselectingandshiftingmech鄄
anism.
14.Gearselecting/shiftingshouldbe
arrangedwell.Thesmallestbending
radiusshouldbe200mmorlarger
thanthat.
Driveshaft
Briefdescriptionofstructure:
Driveshaftofthisloadedtruckisex鄄
posedcardanshaft.Thefrontflange
yokeofdriveshaftassemblyiscon鄄
nectedwithtransmission,whilethe
rearflangeyokeisconnectedwith
reardrivinggearflange.
1.intermediatedrivingshaft
2.rearaxledrivingshaft
Usingandmaintenance:
1.Driveshafthas beencounter鄄
poisedinfactory,itshouldbeen鄄
surednottoimpactinuseandnotto