JAC High end Light Truck. Service Manual - part 5

Plug-in fuse

Starter

132

Insert type fuse
If the head lights or other elements cannot work but the fuse is OK, then you
should check the insert type fuse. If it is already melt broken, change for a new
one. A JAC insert type fuse must be used for the change.
No steel wire is allowed to be used, even if it is temporary use. It will bring
about great damage or even fire.

License light
Screw off the fixing bolts before taking down the glass.

OWNER爷S MANUAL

JAC High end Light Trucks

Fuse in-place tag

Roof light and interior mirror
The lampshade can be simply taken out by hand, and then take down the bulb.

Fuse box
The fuse box is located under glove compartment. Open the fuse box and you
can check and replace the fuse. The box cover can be pulled out by hand.
Please use a pair of nipper pliers to change the fuse.

133

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schematic of different fuse installation

15A 10A 15A 15A 15A 15A 20A 15A 15A 30A

15A 20A 30A 20A 15A 20A 15A 15A 10A 30A

Normal

broken

If the fuse is found broken, check and try to find out the reason for that. Take
necessary maintenance measures before fuse replacement.
Before changing the fuse, turn the start switch to "LOCK" position, and must
use fuses of the same current rating.

134

OWNER爷S MANUAL

JAC High end Light Trucks

Front light set
When replacing bulbs, take down the cover first, then the decoration bands for
the headlights screw off the 4 screws, and the bulbs can be taken out.

Rear light set
When replacing the bulbs, you have to take down the tail light before taking out
the bulb from behind the tail light.

Non-return reflector

Turn signal light

Brake light

Rear light

Rear fog light

Reverse light

135

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136

Battery electrolyte level
The battery electrolyte level should be between the upper and lower scale
marks. If the level is too low, it is necessary to add more distilled water.

Headlights
Properly adjust the headlights, to ensure adequate illumination level on the
highways and no dazzle lighting to drivers in other vehicles head-on. When you
need to adjust the headlights, you'd better contact the authorized JAC service
stations that have special equipment.
The headlights' lighting
Tighten the Screw A for vertical adjustment, and tighten Screw B for horizontal
adjustment.

OWNER爷S MANUAL

JAC High end Light Trucks

User

Power(W)

User

Power(W)

User

Power(W)

Front windshield wiper

Rear fog light

Brake light

25伊2

Front fog light

55伊2

High beam

60伊2

Low beam

55伊2

Reverse light

20伊2

CD set

Electric horn

Marker light

10伊5

Blower

120

Turn signal light

21伊4

Ceiling light

Instruments

Others

Replacement of bulbs
The removable parts of all lamps are illustrated respectively for reference.
The switches must be turned off when replacing the bulbs and only bulbs of the same rating can be used. The standard
bulb ratings are listed below:

137

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Washing of battery
If the exterior parts of the battery are dirty, use warm water to wash them. To
prevent corrosion, apply a thin layer of Vaseline or grease to the surface of the
terminal stud of the battery.

Specific gravity of the battery electrolyte
If the electrolyte hydrometer reads 1.26 at 20益, it can be deemed that the bat鄄
tery is fully charged.
If the specific gravity is lower than 1.23, the battery needs recharging.

138

OWNER爷S MANUAL

JAC High end Light Trucks

Recommended brands of lubricants and diesels

For the best performance and the longest service life of your vehicle, proper brands of lube oils and diesels should be
used according to the recommendation in the list below.

Location

Oil products recommended

Quantity

Engine oil sump

diesel engine lube oil

Above CE class

For the viscosity, refer to the list of engine lube oil viscosity vs. temperature

Gearbox

Summer: GL-4/85W-90

2.7

Winter: GL-4/80W-90

Power steering gear

Auto gearbox oil

As needed

Rear axle

Medium load automotive gear oil

Class GL-4

For the viscosity, refer to the list of gear oil viscosity vs. temperature

3.5

Brake fluid reservoir

DOT3 or DOT4

As needed

Clutch fluid reservoir

DOT3 or DOT4

As needed

Wheel bearings

Multipurpose grease or lithium-based wheel bearing grease

As needed

Intermediate bearing of drive shaft

No.2 or 3 universal lithium-based grease for automobiles

As needed

Clutch yoke

No.2 or 3 universal lithium-based grease for automobiles

As needed

Drive shaft slide bushing

Foss EPT-2.5 grease

As needed

Driving universal joint

Foss EPT-2.5 grease

As needed

Engine cooling system

Glycol anti-freezing fluid

with preservative

As needed

Fuel tank

Summer: No.0 quality light diesel

Winter: No.-10 quality light diesel

Ambient temperature below -30益: No.-35 quality light diesel

139

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140

Lube oils must be selected and used carefully according to the lubricated points, and it is especially important to select
proper lube oil viscosity according to the ambient temperature;
Table of diesel viscosity for diesel engines

Table of gear oil viscosity

Infill diesel engine lube oil

Infill gear oil

Lubrication

渊single class冤

enviromment

temperature

渊multilevel冤

Correlation of engine lube oil

viscosity vs ambient temperature

OWNER爷S MANUAL

JAC High end Light Trucks

渊single class冤

Correlation of engine lube oil

viscosity vs ambient temperature

渊multilevel冤

enviromment

temperature

List of lubrication points

Steering gear

drag link

clutch fluid&brake fluid

king steering pin

front hub bearing

tie rod end

engine

rear leaf spring pin

rear hub bearing

differential

rear leaf spring lifting lug pin

king steering pin

front hub bearing
tie rod end

gearbox

drive shaft universal joint

drive shaft slide bushing

rear leaf spring pin

drive shaft universal joint
rear hub bearing

rear leaf spring lifting lug pin

at the first 1000km

every other month or 3000km

every 6 months or 18000km

every 8 months or 24000km

every other year or 36000km

Lubrication points

replace

W:wheel bearing grease

check, infill or lubricate

C: multipurpose grease

E: engine oil

M: lithium-based grease

G: gear oil

B: brake fluid

141

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Guide to lubrication
Change of the engine oil
Remove the drain plug in the lower part of the oil sump, and drain away the
engine oil in the engine crankcase.
Retighten the drain plug after complete drainage of the engine oil in the engine
crankcase and the fuel filter.
Afterwards, pour the new engine oil of the specified grade into the engine
crankcase through the oil filling port in the cylinder head. Note: Hot engine oil
may scald skins, so please wait for the engine to cool down before draining oil.

The engine oil surface level in the oil sump is measured by the dipstick fixed on
the inner side of the engine. When measuring, the engine should not be run鄄
ning, wait for the oil surface to become still before pulling out the dipstick, and
wipe off the oil from the dipstick with clean cotton cloth. Dip the dipstick into the
oil sump again to the bottom, and then pull it out to check the oil level. There
are two scale lines on the dipstick, the engine oil level should not be below the
lower scale, or there will be difficult oil supply. But the engine oil level should
not be over the upper scale line, otherwise there will occur carbon deposition,
fumes and oil permeation, etc. Therefore, apart from constant attention to the

142

OWNER爷S MANUAL

JAC High end Light Trucks

normality of the engine oil pressure, the engine oil surface level should be
checked before driving out and at an interval of 300-500km.

Replacement of gearbox oil
Screw off the drain hole plug (D) in the bottom of the gearbox casing, drain the
oil out of the gearbox casing. Then, infill the specified lubricant oil into the
gearbox casing through the level inspection hole, until the oil level goes up to
the screw plug (L)of the level inspection hole.

143

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144

Replacement of differential oil
Screw off the drain hole plug (D) in the bottom of the rear axle case to drain the
gear oil in it, infill the specified gear oil into the rear axle case through the level
inspection hole, until the oil level goes up to the screw plug (L)of the level in鄄
spection hole.

Replacement of the greases for the front and rear hub bearings
Replacement of the greases for the front and left hub bearings needs disas鄄
sembly and reassembly of the bearings, so please entrust the authorized JAC
service stations to do that. Proper maintenance and driving can prolong the ve鄄
hicle service life, but also can improve the fuel and oil economic efficiency.

OWNER爷S MANUAL

JAC High end Light Trucks

Replacement of steering oil and fluid
Exhaust fluid
1. Jack up the front axle off the ground completely.
2. Remove the oil pipes (2 pieces) between the steering gear and the power
steering oil reservoir.
3. After the steering fluid is drained off, start the engine in short time, turn the
steering wheel right and left to its limit positions without over 15 seconds, until
the residual fluid is completely drained from the steering pipes.

New fluid fill-up
1. Fix the removed oil pipe in the oil pot and infill the specified power steering
fluid.
2. Fill in the power steering fluid up between the scale marks in the oil pot.
Take care that the fluid surface sinks in parallel with the fill-up, so as to keep a
stable level against any air trapped in.
3. Lower down the front wheels onto the ground, start the engine into idle
speed for several minutes, and rotate the steering wheel right and left.
4. Check the level against the scale mark, and add some more if needed.

145

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Lubrication points
Please use multipurpose greases for lubrication of the following points.
King steering pins (4)

Ends of tie rod (2)

146

OWNER爷S MANUAL

JAC High end Light Trucks

Drag link (2)

Rear leaf spring and spring pin (2)

147

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148

Apply Foss EPT-2.5 grease to the following points:
Universal joints and slide bushing

Please apply No.2 or 3 universal automobile lithium-based grease to the fol鄄
lowing parts:
Intermediate bearings

OWNER爷S MANUAL

JAC High end Light Trucks

149

Technical specification

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Model

HFC1035KD

HFC1042K2RD

HFC1042K3RT

Cabin

Single Cab

Double Cab

Engine

HFC4DA1渊E-玉)

HFC4DA1-1渊E-域)

HFC4DA1-2B(E-芋)

Type

in line-4,diesel

in line-4,

ind -cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

Displacement (cc)

2771

Compression Ratio

Max Power (kw/rpm)

57/3600

68/3600

Max Torque (N.m/rpm)

174/2100-2300

202/2100-2300

Transmission

JAC MSB-5M

Speed Ratio

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

Gear Position

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

Final gear ratio

5.375

Brake system

hydraulic brake

Tyre

7.00R16 Rear single

Overall Size渊mm) 渊L*W*H)

4850*1730*224

4850*1730*2240

4875*1715*2215

4918*1868*2154

Rear body size渊mm冤(L*W*H)

3120*1620*400

2080*1620*400

2080*1770*400

Tread (front /rear )渊mm冤

1385/1395

Wheelbase渊mm冤

2490

Min Turing Radius渊m冤

Min Ground Clearance渊mm冤

198

Max Speed渊km/h冤

110

Seating Capacity

2+3

Max Gradeability(%)

Technical specification

150

OWNER爷S MANUAL

JAC High end Light Trucks

Model

HFC1042K3T

HFC1045KRD

HFC1040K/KR1

Cabin

Single Cab

Double Cab

Single/King Cab

Engine

HFC4DA1-2B(E-芋)

HFC4DA1-1渊E-域)

Type

型式

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

Displacement (cc)

2771

Compression Ratio

17.5

Max Power (kw/rpm)

68/3600

Max Torque (N.m/rpm)

202/2100-2300

Transmission

JAC MSB-5M

Speed Ratio

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

Gear Position

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

Final gear ratio

5.375

B301-4.875

D803-6.142

Brake system

hydraulic brake

Tyre

7.00R16 Rear single

6.50-16/6.50R16

6.50-16

Overall Size渊mm) 渊L*W*H)

4850*1730*2240

5320*1880*2150

5745*1866*2213

Rear body size渊mm冤(L*W*H)

3120*1620*400

2540*1770*400

3930/3600*1770*400

Tread (front /rear )渊mm冤

1385/1395

1580/1395

1420,1440/1395

Wheelbase渊mm冤

2490

2800

3000

Min Turing Radius渊m冤

Min Ground Clearance渊mm冤

198

190

185

Max Speed渊km/h冤

110

Seating Capacity

2+3

Max Gradeability(%)

151

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Model

HFC1040K/KR1

HFC1045K9T/K9R1T

HFC1045K9/K9R1

Cabin

Single/King Cab

Engine

HFC4DA1渊E-玉)

HFC4DA1-2B(E-芋)

HFC4DA1-2B1(E-芋)

HFC4DA1-1A渊E-域)

Type

in line-4,diesel

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-coolerturbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

Displacement (cc)

2771

Compression Ratio

17.5

Max Power (kw/rpm)

57/3600

68/3600

80/3600

Max Torque (N.m/rpm)

174/2100-2300

202/2100-2300

220/2100-2300

Transmission

JAC MSB-5M

Speed Ratio

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

Gear Position

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

Final gear ratio

D803-6.142

B1DAB0-5.571

Brake system

hydraulic brake

Tyre

6.50-16

6.50R16/6.50-16

Overall Size渊mm) 渊L*W*H)

5745*1866*2213

5980*1998*2220

Rear body size渊mm冤(L*W*H)

3930/3600*1770*400

4180/3850*1900*400

Tread (front /rear )渊mm冤

1420,1440/1395

1580/1395

Wheelbase渊mm冤

3000

3308

Min Turing Radius渊m冤

Min Ground Clearance渊mm冤

185

Max Speed渊km/h冤

Seating Capacity

Max Gradeability(%)

152

OWNER爷S MANUAL

JAC High end Light Trucks

Model

HFC1045K2/R1

HFC1045K2

HFC1042K

Cabin

Single/King Cab

Single Cab

Engine

HFC4DA1-1渊E-域)

HFC4DA1渊E-玉)

Type

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

diesel

in line-4,diesel

Displacement (cc)

2771

Compression Ratio

17.5

Max Power (kw/rpm)

68/3600

57/3600

Max Torque (N.m/rpm)

202/2100-2300

174/2100-2300

Transmission

JAC MSB-5M

Speed Ratio

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

Gear Position

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

Final gear ratio

B1DAB0-5.571

B1DAB0-6.142

D800-6.142

Brake system

hydraulic brake

Tyre

6.50R16/6.50-16

7.00R16

Overall Size渊mm) 渊L*W*H)

5980*1998*2220

5980*1998*2200

5980*1880*2200

Rear body size渊mm冤(L*W*H)

4180/3850*1900*400

4180*1770*380

Tread (front /rear )渊mm冤

1580/1395

1440/1425

Wheelbase渊mm冤

3308

3360

Min Turing Radius渊m冤

Min Ground Clearance渊mm冤

185

190

Max Speed渊km/h冤

100

Seating Capacity

Max Gradeability(%)

153

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Model

HFC1040K2

HFC1042KR

HFC1042K2T/K2RT

HFC1042K

Cabin

Single/King Cab

Double Cab

Single/King Cab

Double Cab

Engine

HFC4DA1-1渊E-域)

HFC4DA1-2B(E-芋)

Type

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

Displacement (cc)

2771

Compression Ratio

Max Power (kw/rpm)

68(80)/3600

68/3600

Max Torque (N.m/rpm)

202(240)/2100-2300

68kw/3600

202/2100-2300

Transmission

JAC MSB-5M

Speed Ratio

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

Gear Position

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

Final gear ratio

D800-6.142

Brake system

hydraulic brake

Tyre

7.00R16

Overall Size渊mm) 渊L*W*H)

5995*1900*2250

5995伊1900伊2250

5995*1900*2250

Rear body size渊mm冤(L*W*H)

4230/3900*1790*400

3200伊1790伊400

4230/3900*1790*400

*1790*400

Tread (front /rear )渊mm冤

1440/1425

Wheelbase渊mm冤

3360

Min Turing Radius渊m冤

Min Ground Clearance渊mm冤

190

Max Speed渊km/h冤

100

Seating Capacity

2+3

Max Gradeability(%)

154

OWNER爷S MANUAL

JAC High end Light Trucks

Model

HFC1042K2T/K2RT

HFC1042K

HFC1035KD

HFC1020K/KR1

Cabin

Single/King Cab

Double Cab

Single Cab

Single/King Cab

Engine

HFC4DA1-2B1(E-芋)

HFC4DA1-1渊E-域)

HFC4DA1渊E-玉)

Type

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

in line-4,

ind-cooler turbocharged,

diesel

in line-4,diesel

Displacement (cc)

2771

Compression Ratio

Max Power (kw/rpm)

80/3600

92/3600

77/3600

Max Torque (N.m/rpm)

202/2100-2300

174/2100-2300

Transmission

JAC MSB-5M

Speed Ratio

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

5.529袁2.782袁

1.641袁1袁

0.785袁R尧5.271

Gear Position

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

1 3 5

2 4 R

Final gear ratio

D800-6.142

5.375

D870-6.142

Brake system

hydraulic brake

Tyre

7.00R16

7.00R16 Rear single

hydraulic brake

Overall Size渊mm) 渊L*W*H)

5995*1900*2250

4850*1730*2240

5400*1868*2200

Rear body size渊mm冤(L*W*H)

4230/3900*1790*400

*1790*400

3120*1620*400

3580/3250*1710*370

Tread (front /rear )渊mm冤

1440/1425

1385/1395

1440/1395

Wheelbase渊mm冤

3360

2490

2800

Min Turing Radius渊m冤

Min Ground Clearance渊mm冤

190

198

185

Max Speed渊km/h冤

100

110

Seating Capacity

Max Gradeability(%)

Technical specification

155

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