JAC HFC1035KD, HFC1042K2RD, HFC1042K3RT, HFC1042K3T, HFC1045KRD Service Manual

All information in this Owner's manual is current at the time of publication. However JAC reserves the right to make changes at any time so that our police of continual product improvement may be car ried out.

This manual applies to all current JAC models equipped with 4DA1series engine explanation of op tion as well as standard equipment. As a result, you may find material in this manual that does not apply to your specific vehicle.

Foreword

T hank you for choosing JAC. We are pleased to welcome you to the growing number of different people who drive JAC. The advanced engineering and high-quality construction of each JAC we build is something of which we are proud.

This Owner's Manual will introduce you the features and operation of your new vehicle. It is suggested that you read it carefully since the information it contains can contribute greatly to the satisfaction you receive from your new vehicle.

The manufacturer also recommends that all service and maintenance on your vehicle be performed by an authorized JAC dealer. JAC dealers are prepared to provide high-quality service, maintenance and any other assistance may be required.

ANHUI JIANGHUAI AUTOMOBILE CO., LTD.

May. 2008

Contents

Page

Importance 1 Locations of chassis number and engine number 2 Location of the vehicle nameplate 2

Overload 3

Information about new vehicles 5 Vehicle operation and management 7 Maintenance 7 Cabin tilting mechanism 8

Cabin lockup 10

Controller and instrument 13 Cabin heater, defroster, air conditioning 35 CD and Radio 43 Before driving 51

Operation of controllers 52 Daily check list for drivers 60

Driving 71 Preparations before startup 72 Engine startup 73 Before vehicle running 74 Engine stopping 76 Parking 77 Attention poitns for driving 78 Economic driving 83 Vehicle management and maintenance in winter 86 Running on ice or snow 88

In emergence cases 90

Repair and maintenance 101 Schedule of regular maintenance 104 Guide to maintenance 108 Recommended brands of lubricats and diesels 139 Lubrication 140 List lubrication point 141

Guide to lubrication 142

Technical specification 149

Importance

1

OWNER S MANUAL

JAC High end Light Trucks

The followings are very important for the correct management and economic use of JAC vehicles, and they shall be read carefully before use and maintenance.

Locations of chassis number and engine number

Please note down the chassis number and engine number, so as to give them to the specified JAC maintenance stations in case of repair and maintenance.

Chassis number

The chassis number, which is VIN code number, is stamped on the outer side of the right longeron end of the frame.

Engine number

The engine cylinder head is affixed with the engine tag, on which it is marked with information about the engine, such as its model, serial number, nominal horse power, rated engine speed, ex-works date, etc.

Location of the vehicle nameplate

The embossed number of VIN code for vehicle and Type II chassis is located on the outer side of the right longeron of the frame as well as, on the back side of the rear support of the rear leaf spring. Besides, an individual tablet of VIN

2

code is attached on the dashboard near the right column.

Overload

Overloading will shorten vehicle's service life, but also bring about potential risk to safe driving.

The loading mass must be limited to the specified range of the max. total mass for vehicle, and the load distributions on the front and rear shafts shall not be more than the carrying capacity of the vehicle shafts. Please refer to the techni cal specification sheet for the rated total mass value and shaft loading capacity.

3

Information about new vehicles

5

OWNER S MANUAL

JAC High end Light Trucks

Careful driving and maintenance during the run-in period will play a crucial role in improvement of the performance and service life. So, the followings must be strictly abided by during the initial run-in peri od of 3000km:

1.During the initial 3000km driving, the vehicle speed shall not be more than 70% of the max. engine speed. Attention should be paid to the tachometer dur ing driving to avoid engine over speed running.

2.Try to avoid engine over speed running, abrupt startup or unnecessary e mergency braking.

3.It is necessary to have the engine in idle running before driving each time, until it comes up to the normal working temperature.

6

Vehicle operation and management

All the components and devices of the vehicles shall be checked according to the requirements in sections of "Controllers and instruments" and "Driving";

Maintenance

For driving safety, vehicle reliability and good performance, the requirements in the section "Maintenance" should be followed in check and adjustment.

Note

1.No refitting or unauthorized installation of any equipment is allowed on JAC vehicles. Our Company will not be responsible for any losses due to unautho rized refitting or installation of any equipment!

2.If any problem occurs during the use of our products, make sure to have

them sent to the specified JAC service station for maintenance; please see clearly the genuine parts of JAC vehicles if any parts need to be changed.

3. Correct run-in of new vehicle has much to do with longer service life, reliability and economy. It is specified that new

7

OWNER S MANUAL

JAC High end Light Trucks

Safety hook pull-rod

Operating handle

vehicle run -in mileage is 2500 -3000km, with the max. speed not more than 80km/hour.

4. During your use of our products, please have maintenance in time referring to the "Instruction Manual" attached with the vehicle, in order to bring your ve hicle's good performance into full play.

Cabin tilting mechanism

As shown in the figure, single cabin or one-and -half -row cabin can be tilted upward and forward by 40 degrees for easy maintenance.

To begin tilting, turn the pulling support with left hand to pull out the safety hook tie bar, and pull outward the operating handle with right hand.

Tilting puller holder	Limit handle

With the operating handle released, hold firm the tilting puller support with left hand, and pull the limit handle outward with right hand. The cabin will tilt for ward for a certain degree after the handle opened.

When the cabin tilts to a certain angle, hold the tilting puller support with right hand, continue tilting the cabin upward with force.

8

9

OWNER S MANUAL

JAC High end Light Trucks

self-lock handle

When the cabin tilts to a certain angle, the self -locking handle on the tilting support will automatically locks in by the spring tension, and the handle will support the cabin then.

		Cabin lockup
		With left hand holding firmly the tilting puller support, open the self-lock handle
	Tilting puller holder Self-lock handle
		upward and backward with right hand. The cabin will tilt downward by itself due
		to the deadweight.
		Attention: Keep your head and hands away from under the cabin when it is tilt
		ing downward by itself.

When going down to a certain angle, the cabin will slow down. Hold the tilting puller support and press it down with left hand, until the lock hook get engaged in the hook limit support on the frame.

Then hold the operating handle with right hand and press it down, until the safety hook securely locks the operating handle.

10

11

Controller and instrument

13

OWNER S MANUAL

JAC High end Light Trucks

	2	3	4	5	6	7	8	9	10	11

12 13

14	15	16	17	18

14

1.Switch

2.Instrument panel vent

3.Combined switch handle

4.Steering wheel

5.Instruments

6.Horn button

7.Windshield wiper/cleaner handle

8.Air conditioner switch

9.Ashtray

10 Radio

11 Tea cup holder

12 Manual accelerator knob

13 Ashtray

14.Clutch pedal

15.Brake pedal

16.Accelerator pedal

17.Cigarette lighter

18.Glove compartment

Tachometer

The tachometer indicates the engine 's round per minute. The red zone means the critical rpm.

When the tachometer hand is in the red zone of the scale plate, driving is not allowed. If a driver does not stop the vehicle when the tachometer hand is get ting into the red zone, serious damage will occur to the engine.

Fuel gauge

It indicates the present fuel level in the fuel tank, "F" stands for "Full", and "E" stands for "Empty".

Fuel tank should be always replenished in time to avoid fuel shortage during driving.

15

OWNER S MANUAL

JAC High end Light Trucks

Temperature gauge

It shows the engine coolant temperature. If the hand is in the red zone when engine is running, it means the engine is overheat. Always pay attention to keeping the engine temperature at normal degrees.

Note:

There will be some difference between the actual temperature and the temp. reading of the tachometer due to the surrounding and driving conditions.

If the temperature inside and outside the vehicle is below -30 or above 70 de grees, it will bring about inexact temperature reading values.

Turn signal indicator light (green)

When a turn signal lamp is flashing, its indicator light will flash on and off. If the flash is very short in interval, it is possible that the turn signal connected with it has some problem or maybe one of the bulbs is burnt down.

High beam indicator light (blue)

The indicator light will be on when the high beam is on.

Diesel warm-up indicator light (light yellow)

When pressing the warm-up switch in "ON" position, this indicator light is on. The time when the indicator light is on depends on the water temperature.

16

17

OWNER S MANUAL

JAC High end Light Trucks

Low fuel level warning light (light yellow)

This light will be on when the fuel oil level is very low in the tank. Fuel oil should be added at once.

Oil pressure warning light (red)

It is on when the ignition switch is in "ON", and is off after the engine is started. If this light is on during engine running, stop the engine immediately, and get in touch with the nearest JAC vehicle dealer.

Charging warning light (red)

When the ignition switch is in "ON" position, this light is on, and becomes off af ter the engine is started. If the light remains on during the engine running, it means something wrong with the charging system. Check the V belt for any damage, and contact the nearest JAC vehicle dealer.

Rear fog light indicator light

This indicator light gets on when the rear fog light is turned on.

18

19

OWNER S MANUAL

JAC High end Light Trucks

Water quantity indicator light of the fuel filter

When water in the oil/water separator reaches a dangerous level, the water quantity indicator light of the fuel filter is on. If the indicator light remains on dur ing the engine running after it is on, it means that water in the oil/water separa tor should be drained out.

Windshield wiper working indication

Turning the operation handle in horizontal clockwise may control the windshield wiper. Turn the operation handle 12 degrees clockwise into the INT position, the windshield wiper will work intermittently in 5-10 seconds; turn the handle 12 degrees clockwise into the L0 position, the wiper will work at the low speed level; turn the handle further 12 degrees clockwise, and the wiper will work at high speed level; when the handle gets into the starting position, the wiper will automatically be turned off or reset.

Washer indication

The washer control button is at the end of the operation handle, and the windshield washer is installed near the right door and below the instrument panel. When the washer control button is pressed in, detergent (anti-freeze solution for winter time) will be injected out of the washer through the nozzles onto the windshield.

Danger warning switch

Pressing this switch, located in the lower left corner of the dashboard, will sound an alarm, at this moment all the turn signal lamps will be flashing, and have nothing to do with the positions where they are. Press it again, the switch will reset.

When vehicle meets with any danger that may cause traffic accident, this dan ger warning light shall be used in day and night to sound an alarm to other drivers.

20

21

OWNER S MANUAL

JAC High end Light Trucks

Fog light switch

When this switch, located in the lower left corner of the dashboard, is pressed, all the fog lights will be turned on, and one more press will have a reset.

When vehicle meets with any danger that may cause traffic accident, this dan ger warning light shall be used in day and night to sound an alarm to other drivers.

Preheating switch

When this switch, located in the lower left corner of the dashboard, is pressed and held down in "ON" position, the indicator light is on. The holding down time is dependent on the water temperature, normally about 30 seconds.

If the ambient temperature is below zero or even lower, press this preheating switch before starting the vehicle in order to raise the inlet air temperature for the engine to achieve smooth startup.

22

Combination switch

Located below the steering wheel, it consists of steering shaft lock seat, ignition startup lock and the ignition switch.

Ignition switch

Located to the right of the combination switch, the ignition switch serves as 4 functions like LOCK, ACC, ON and START. See left Fig. for the positions shown. Insert the key into LOCK position, the ignition switch is powered on and unlock the steering gear. Turn the key clockwise into ACC position, the auxil iary devices circuits are powered on, such as radio and tape player, etc. Turn the key to ON position, the instruments circuits are powered on. Go on to turn the key to START position, the engine is started. Release the key as soon as the engine is started, and the key will go back to ON position under the spring force.

23

OWNER S MANUAL

JAC High end Light Trucks

Cigarette lighter

It is in the lower right to the steering wheel. If you want to use it, press it inward for about 15 seconds, with the ignition switch key in "ON" position, and then re lease it. It will heat up enough for use before automatically going back to its normal position.

1.Do not hold on the cigarette lighter after it is pushed in, otherwise it will be overheated and may cause fire.

2.If the cigarette lighter fails to auto come back to its normal position in 18 sec onds , it means it has something wrong, and you must manually pull it back to its normal position.

3.Do not leave the cabin with the cigarette lighter pushed in, otherwise it may cause unexpected fire.

4.A deformed cigarette lighter cannot correctly recoil to its original position. If it is found deformed, please replace it with a true JAC spare part.

Left ashtray

Pull out the ashtray for use. Pull out the ashtray further while pressing the posi tioning spring, and it may be taken out for cleaning purpose.

Turn back and close the ashtray after use, otherwise the still burning cigarette may ignite other butts and cause possible fire.

Right ashtray

Pull out the ashtray for use. Pull out the ashtray further while pressing the posi tioning spring, and it may be taken out for cleaning purpose. Turn back and close the ashtray after use, otherwise the still burning cigarette may ignite other butts and cause possible fire.

24

25

OWNER S MANUAL

JAC High end Light Trucks

Controller on the floor pan Gearshift lever

Each time before you shift the gears, you should first step on the clutch pedal to the end. The gear shift chart is on the top of the gearshift lever. With the key in "ON" position, the backing indicator light will be on if the gearshift lever is moved to the Reverse gear position.

Accelerator pedal

To avoid unnecessary fuel consumption, operate the accelerator pedal in a proper and balanced way according to the need.

Brake pedal

To avoid sharp braking, the brake pedal should be operated smoothly. When driving along a down slope, you should use the foot brake pedal now and then while using the vent as auxiliary braking means.

If engine cut-out occurs during running, the brake booster will not fully function, and the braking effect will be lowered.

In such a case, step on the brake pedal with force to have enough braking ef fect.

Clutch pedal

The clutch pedal must be stepped on to the end when it is used, otherwise the gears in the gearbox will give out friction noises, and the clutch -plate will be worn out soon.

Foot off the clutch pedal when not using it.

26

27

OWNER S MANUAL

JAC High end Light Trucks

Others Glove box

Pull out and the upper part of the glove compartment will open.

The glove compartment should be closed during driving to avoid any articles from bouncing out.

Sun visor

If the head -on sunshine is dazzling, the sun visor can be lowered down to shield the sun light. This sun visor may also be hooked off and turned to the side for use.

Ceiling light rearview mirror

No matter which position the startup key is in, the ceiling light in the cabin can be turned on or off.

"OFF" position: this light is in off state.

"Door" position: when the side door of the cabin is opened, this light will be on.

"Powered" position: no matter what kind of state the door is in, this light will be on.

Standby water tank for radiator

The standby water tank for the radiator is installed on the right side of the frame.

Check the cooling water level and make up cooling water at the standby water tank. Do not open the injection port cover at the radiator unless needed partic ularly. See the "Maintenance" for details.

28

29

OWNER S MANUAL

JAC High end Light Trucks

Fuel tank cap

The fuel tank cap is on top of the fuel tank, and it can be screwed off counter clockwise.

Fluid reservoir for brake and clutch

The fluid reservoir is installed by the instrument panel near the driver side.

Spare tire hanger

The spare tire is fastened to back of the frame. To lower down the spare tire, insert the handle into the hole in the rear cross beam to connect it with the snap-lock, and then turn the handle counterclockwise.

How to open and close the rear board

Turn the handles on the right and left sides both upward for 180 degrees, and the rear board can be released. To closed it, turn the board close first before turning down the handles to fasten it.

30

31

OWNER S MANUAL

JAC High end Light Trucks

Right and left side boards

1.Release the lock knuckles of the rear board.

2.Move the fastened handle leftward before putting down the vertical lock out wards to release it.

3.Lift up the hook handle on the front end of the side board to release the front hook.

4.At this time, the front end of the side board is still fastened by the board clamp. Pull out the board clamp with force to let free the side board.

5.To close the side board, securely lock up the front end of side board with the hook handle, and put it into the vertical lock of the rear board before fastening it with the handle.

Turm signal light						Rear fog light
						Reverse light
Brake light
	Rear light
				Non-return reflector

Outer lights

Front:

1.Front turn signal lamps; 2.Fog light;

3.Front side-marker light; 4. Headlight.

Rear:

The rear light set is installed in the position shown on the left figure, with the following:

1.Back-up light;

2.Turn signal lights;

3.Brake lights;

4.Rear side-marker light;

5.After-reversion reflector.

32

33

OWNER S MANUAL

JAC High end Light Trucks

Antenna:

Please pull out the antenna if a better sensitivity of radio is desired.

The antenna should be retracted if the vehicle is to be parked in a garage lower than a house or to be washed.

Cabin heater, defroster, air conditioning

34

35

OWNER S MANUAL

JAC High end Light Trucks

Air outlet control knob

Use different knobs to regulate the air from the heater, defroster and the air conditioner, or the air flow out of the ventilation outlet.

Plane air outletDual planesBottom air outlets

Bottom air outlet and defrosterDefroster

Plane air outlet

Air is regulated when it passes the system, and is vented from the upper air outlet.

This position is used for most of the air conditioning cases.

1.	Temp. control knob	3. Air inlet control bar
2.	Fan flow knob	4. Air outlet control knob
36		37

OWNER S MANUAL

JAC High end Light Trucks

Dual planes

Air is regulated and discharged from the upper air outlet and floor air outlet. The air out of the floor air outlet is warmer than that from the upper air outlet in the range of dual planes. But when the temperature control knob is turned to " Warmest" or "Coldest", the air from the floor air outlet is the same as that from the upper air outlet.

Bottom air outlet

Air is discharged from the bottom air outlet.

Bottom air outlet and defroster

Air is discharged from the bottom air outlet, and small part of air is discharged from the air outlets of defroster and the side window defroster.

Defroster

Air is regulated and discharged from the air outlet of the defroster; small part of air is discharged from the side-window defrosting air outlet. This position is on ly recommended for heavy fog and freezing.

38

39

OWNER S MANUAL

JAC High end Light Trucks

Move this selection rod leftward or rightward to control input of ambient air and the circulation of the inner air.

Note: Only prolonged circulation of the inner air will make the windshield blurred. For the sake of good ventilation, it is better to exchange with the air from outside.

Temperature control knob

Turning this control knob may control the inside temperature within the range of temperatures indicated on the instrument panel.

Fan air flow knob

Turn the knob as per the following to control the air output.

OFF: Fan is powered off.

1......	Fan is set in low speed range 2......Fan is set in medium to low speed
range
3......	Fan is set in medium to high speed range
4......	Fan is set in high speed range

Air conditioner switch

Press the "A/C" switch to put the air conditioning system into operation. The LCD in the switch will be on when the system is under operation. Press this switch again ,and the air conditioning system is switched off.

If the fan control rod is in off position, instead of any position in the range of fan speed settings, the system can not be put into operation.

40

41

CD and Radio

43