JAC Truck HFC1061-1063-1083. Service Manual — part 2

when the engine works at an over
fast speed to avoid accelerating the
wear of the synchronizer.
5. When shifting, the force should be
gentle. The hand force must be act鄄
ed on the control rod until the gear
reaches the correct position. Shifting
with flap of push and loosening is in鄄
appropriate and the shifting opera鄄
tion cannot be accomplished easily
in this way.
6. You can shift from forward gear to
reverse gear or from reverse gear to
forward gear only after the vehicle
stops stably, or else, the gear can be
damaged.
7. The fifth gear is over-speed gear,
it can be used when the vehicle
speed is over 50 km/h to avoid dam鄄

age of the over-speed gear resulting
from over loading .
8. During driving, if there is any ab鄄
normal noise in the transmission,
stop the vehicle and check it to elimi鄄
nate the malfunction.
9. When sliding on the downgrade,
stalling of the engine is not allowed;
starting the engine with the inertia of
sliding on the downgrade is forbid鄄
den in case of damage of the gear
and the synchronizer.
10. During breaking-in period of the
new vehicle, because the metal
chipping which is produced by the
frictional function between new parts
does harm to components in the
transmission, especially to the dura鄄
bility of the conical rings of the syn鄄

chronizer, so the lubricating oil
should be replaced after the break鄄
ing-in period of the new vehicle ex鄄
pires. Under general condition, re鄄
place the lubricating oil once for ev鄄
ery 6000 km running. When replac鄄
ing the lubricating oil, first drain off
the oil in the transmission, prop up
the rear axle, shift the transmission
into the reverse gear, add kerosene,
keep the transmission rotating for 2耀
3 minutes, then drain off kerosene,
add pure gear oil.
11. Check the oil level in the trans鄄
mission frequently, if the oil level is
under the lower edge surface of the
oil filler bolt hole, sufficient oil should
be added.
12. Check the outside bolt of the

34

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

35

transmission and the flange of the
second shaft for tightening and
working condition of the components
in the transmission frequently. Be鄄
cause the vent plug is easy to block
by dust, which causes increasing
pressure in the transmission, oil
seepage or leakage, so the vent plug
should be cleaned periodically.
13. The movement part of shifting
operation component should be lu鄄
bricated well, or else, it will be hard
to shift because of the wearing of the
movement parts. If the position of
gear selecting is found incorrectly, or
gear shifting is difficult or the trans鄄
mission is out of gear automatically
in using, firstly you should readjust
the gear selecting and shifting mech鄄

anism.
14. Gear selecting/shifting should be
arranged well. The smallest bending
radius should be 200mm or larger
than that.

Drive shaft

Brief description of structure:
Drive shaft of this loaded truck is ex鄄
posed cardan shaft. The front flange
yoke of drive shaft assembly is con鄄
nected with transmission, while the
rear flange yoke is connected with
rear driving gear flange.

1. intermediate driving shaft
2. rear axle driving shaft
Using and maintenance:
1. Drive shaft has been counter鄄
poised in factory, it should be en鄄
sured not to impact in use and not to

knock and stack when doing disas鄄
sembly and assembly work or carry鄄
ing. Replace for a new one if the
shaft is distorted or the balancer is
desquamated, otherwise, there will
be vibration, noise, and extra impact
in running, which can damage other
assemblies and even endangered
running.
2. Check oil seals of center support鄄
ing bearing, needle bearing of cross
shaft, sliding spline regularly, replace
invalid oil seals instantly
3. When doing class -one mainte鄄
nance, lubricate the universal joint,
slide spine and intermediate bearing.
When adding lubrication to the uni鄄
versal, extrude the oil pistol quickly
to fully lubricate the needle bearing

of universal joint, check and tighten
drive shaft and the connecting bolt in
every position of intermediate sup鄄
port.
When doing class-two maintenance,
check whether the dust cap drop
and whether the universal joint's free
rotate motion get stuck. When the
cross shaft lies in the needle bear鄄
ing, tear down the universal joint if
the radial play is too wide. Replace
the needle bearing or cross shaft ac鄄
cording to your requirement
When doing class -three mainte鄄
nance, disassembling the drive shaft
is necessary, pay attention to making
the mutual mark for the flange yoke,
cross shaft and connecting yoke. For
slide spline shaft, make the cooper鄄

ative mark on the flange so as to
mount on the original position. After
finishing all the maintenance items,
having balanced check again is bet鄄
ter. The standard of dynamic bal鄄
ance is 2750 turn per minute and the
unbalanced volume is less than
144g/cm

36

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

Rear axle

Brief description of structure:
Rear axle is single reduction driving
axle, which is composed of final
drive and differential and axle hous鄄
ing. It is medium and final class
speed reduction driving mechanism
in driving system. Final drive can not
only change the direction of driving
force, but also reduce the rotate
speed. It's composed of drive pinion
and driven gear and final drive. The
drive pinion is connected with drive
shaft, whose end with spline is con鄄
nected with universal joint assembly
by coupling flange. Driving bevel
gear's toe end axle journal is mount鄄
ed on guiding cylindrical roller bear鄄
ing and bears radial force only.

Driven gear is also called crown gear
and is fixed to left half flange of the
differential case with bolts. Differen鄄
tial is a kind of device that is com鄄
posed of differential case, cross
shaft and four planetary pinions is a
device that makes the left wheel and
the right wheel run at a different
speed when necessary. Rear axle
housing is an integrated axle housing
that is made of welding punched ar鄄
mor plate.
Final drive's tooth face meshing and
adjustment of gear lash
1. Check drive gear bearing's pre -
tension level. The pre -tension force
of drive gear bearing should be ad鄄
justed. When measuring bearing
case's bolt hole , tangential stress is

15-30N.
2. The adjustment of drive gear bea-
ring's pre-tension force is a process
of adding and reducing number of
adjusting shim. When adjusting shim
adds, friction moment will be re鄄
duced. When adjusting shim re鄄
duces, friction moment will be
added. Thickness of friction moment
has three norms of 0.40mm, 0.45mm,
0.50mm.
3. Check final drive for meshing be鄄
tween drive pinion and driven gear .
The contact area and side play be鄄
tween drive pinion and driven gear
can be adjusted by means of adjust鄄
ing shim and adjusting collar of dif鄄
ferential bearing. There are four kind
of shims according to thickness,

37

0.30mm,0.40mm, 0.45 and 0.5mm.
Normally, the clearance between
these two gears is 0.15 -0.25mm,
while the side play ranges under
0.07mm. To adjust side play, mea鄄
sure four points with equal angle
around the driven gear, and the
gauge outfit of micrometer should be
in a vertical position.

To adjust tooth contact area, driven
gear should be coated with red lead
in three points, and 2-3 teeth should
coated in every point. Then rotate
gears clockwise and anti -clockwise
to get the trace of contact area. (see
the right figure). If tooth contact area
doesn't conform to the requirement
showed in figure (a), adjust it to con鄄
form to the requirement. If trace devi鄄
ate from convex or concave tooth
root, add adjusting shim. If trace de鄄
viate from convex or concave tooth
top, reduce adjusting shim.
Correct contact trace should deviate
from toe end of tooth, as figure (a),
trace deviate from convex or con鄄
cave tooth root, as figure (b), trace
deviate from convex or concave

tooth top, as figure(c).
Adjustment of rear axle's hub bear鄄
ing: tighten the bearing lock nut to a
certain force moment and release 1/
3 -1/4 circle. Pre -tightening force
moment is 490-588N.m
Maintenance of rear axle:
1. Hyperbola bevel gear requires a
strict standard of lubricating, only
can be filled with specified gear oil.
Don't use or mix with other gear oil,
or else, it will result in quickened
scratch and wear.
2. Don't remove or adjust the conical
gears and bearings of final drive, for
they have been matched and adjust鄄
ed in factory. Removing and adjust鄄
ing should be done only as the gears
are worn and the gear clearance is

38

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

beyond the specified value or the
bearing axial clearance is too large,
or the damaged parts must be re鄄
placed.
3. Clean the vent plug regularly, dis鄄
assemble it when doing class -one
maintenance to make sure ventilation
expedite. A jammed air drain can
bring higher air pressure in the rear
axle, which will result in lubricant leak
from the drive pinion seal and other
welding line. Check the level of lubri鄄
cant in axle housing.
4. For a new vehicle, lubricant should
be replaced when doing class -two
maintenance. Afterwards, check the
quality of lubricant during class-two
maintenance every time. Replace
new lubricant if color -change or

thinness has taken place.
5. Dismantle the rear cover when do鄄
ing class -three maintenance. Clean
the inner cavity and final drive as鄄
sembly, screw bolt and nut referring
to the specified force moment.

Frame

Brief description of structure:
Truck of this series is of side-mem鄄
ber structure.
Using and maintenance
Side member, cross member and
every component fixed on the frame
are connected using rivet or thread
and welding. Only when all the com鄄
ponents are in perfect condition, can
the frame be used well. Having over鄄
all check when doing class -three
maintenance. Tighten the rivet and
thread if they loose and renovate the
cross member in time if there are
crack and shape distortion on it.
Shape distortion and damage of
frame have close relationship with
overloading and parking location and
driving condition (vehicle speed and
road condition).

39

1. front bumper bracket assembly
2. the first cross beam
3. the first cross beam reinforced
plate
4. the second cross beam as鄄
sembly
5. front spring fixed support as鄄
sembly
6. side member

7. engine front support assembly
8. front steel spring limit stop
9. engine front support outer sup鄄
port
10. cab's rear support assembly
11. front spring shackle bracket
12. cab's rear support assembly
13. the third cross beam assembly
14. the fourth cross beam

15. frame's rear spring front rein鄄
forced plate
16. frame's reinforced plate
17. the fifth cross beam reinforced
plate
18. the fifth cross beam
19. rear shock absorber's support
assembly
20. rear spring fixed support

21. additional spring support
22. the sixth cross beam coupling
plate
23. the sixth cross beam
24. frame's rear spring rear rein鄄
forced plate
25. frame's reinforced plate
26. spare-tire carrier cross member
27. rear cross member

40

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

Suspension

Brief introduction of the structure:
The suspension of this series of

trucks is composed of leaf spring and
bi -directional hydraulic telescopic
shock absorber. There is transverse

stabilizer mounted forward and back鄄
ward. The next figure shows our front
suspension assembly.

41

1.front leaf spring
2.front saddle clamp bolt
3.damping ring

4.shock absorber
5.front shock absorber supporter

1. frame
2. rear leaf spring
3. rear center bolt

4. rear absorber
5. secondary spring bracket
6. rear shackle clamp

Using and maintenance of leaf spring
1. When vehicle runs for 200km and
500km during the beginning of
break -in period, check and tighten
U-type bolt on leaf spring with spec鄄
ified torque under load bearing state.

2. After break-in period, tighten U-
type bolt on leaf spring with speci鄄
fied torque when vehicle is fully
loaded. Do it also when leaf spring is
replaced or reset for running every
2000-3000km.

3. Tighten U - type bolt on leaf
spring with specified torque when ve鄄
hicle is fully loaded for running for
2000km-3000km.
4. Check and tighten exposed bolts
and nuts of the suspension (with ve鄄
hicle fully loaded) when doing class-
one maintenance. Check rubber
parts of the suspension, if the rubber
parts are worn greatly, replace them
instantly.
5. When doing class -two mainte鄄
nance, carry out class -one items
and dismantle the leaf spring as well
as lubricating it, check the transverse
stabilizer rod at the same time.
6. When doing class -three mainte鄄
nance, carry out class-two items and
dismantle all the rubber parts and

42

The next figure shows rear suspension assembly.

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

replace new ones.
7. When replacing leaf spring and
dismantling or assembling center
bolt, pay attention to the assembling
direction of front and rear steel plate.
When tightening leaf spring U -type
bolt and nut, screw it using well-dis鄄
tributed force at first, then screw front
U -type nut according to specified
force moment and screw rear ones.
Using and inspection of shock ab鄄
sorber:
1. Check the absorber for tempera鄄
ture after running a certain length on
bad road surface (usually more than
10km) There is no resistance if the
temperature is low ( lower than air
temperature) and shock absorption
doesn't function. If one absorber has

much lower temperature than the
symmetrical one, the lower one's re鄄
sistance is much more smaller. Low鄄
er resistance result from lacking in oil
or from damage of some important
parts, and the absorber that lack in
resistance should be removed to in鄄
spect.
2. Check the shock absorber for oil
leak if continuous abnormal vibration
is detected in running.Oil leak should
be dealt with in time, so that the
shock absorber can work normally.
3. Check absorber when maintaining
vehicle. To check absorber, stick up
it and hold its lower end by vise,
then pull and press it for several
times. Normally the resistance is
bigger when pulled, otherwise the

absorber is damaged or lack in oil.
Repair and replace parts and add
absorber oil in time to avoid serious
damage.
4. If it's necessary to replace ab鄄
sorber rod, replace oil sealing at the
same time. If necessary, don't dis鄄
mantle valve parts casually.
5. When doing class -three mainte鄄
nance, dismantle and clean the ab鄄
sorber,replace the absorber oil.Don't
forget cleaning when adding oil.

43

Front axle

Brief description of structure:
Front axle assembly is composed of
front axle, steering knuckle, left
&right steering knuckle arms, king
pin, front brake and tie rod etc.
Adjustment of front axle:
1. Adjusting of the front wheel hub
bearing: To adjust front hub bearing
in axial retightening force, tighten
fastening nut with wrench, and
loosen knuckle nut for about 120益 .
Rotate the hub clockwise and anti -
clockwise, make sure that roller a鄄
gainst the tapered contact the bear鄄
ing outer race properly, then tighten
nut to the position where the rabbet
aims the split pin hole. Check the
hub if it can rotate freely and don't
swing a lot. Now, distort the split pin
and fix it.

44

1.tire nut
2.front hub bolt
3.front hub and brake
drum assembly
4.front hub inside nut
5.hub cap
6.steering knuckle

7.lock plate
8.hub outside gearing
9.hub inside gearing
10.oil seal
11.oil seal carrier
12.oil guard
13.brake bottom plate bolt

14.bush
15.king pin
16.king pin latch
17.nut
18.steering stop bolt
19.steering knuckle pin
bush assembly

20.thrust bearing
21.steering knuckle king
pin lid
22.steering bending arm
23.tie rod assembly
24. front axle

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

2. Adjustment of clearance between
knuckle and front axle: The clearance
is adjusted via adjusting shim, it
should be less than 0.1mm. Use
thrust washer to adjust its clearance.
3. Adjustment of toeing -in. The toe鄄
ing -in can be adjusted via adjusting
tie rod. Park the vehicle on a flat
ground, jack up its header and orient
front wheel just as vehicle run for鄄
ward. Loosen locking nuts of tie rod,
rotate the tie rod till the toeing -in fit
the specified size. Then tighten the
locking nuts.
Using and maintenance:
1. When doing class -one mainte鄄
nance, check tightening situation of
each nut. Lubricate longitudinal and
tie rod ball pin, steering knuckle king

pin and bush.
2. When doing class -two mainte鄄
nance, carry out class -one mainte鄄
nance items as well as doing some
checking. Check whether there is
damage and crack on steering
knuckle, steering knuckle bending
arm and left and right steering
knuckle arm. Check the fitness of
steering knuckle king pin and bush.
Check the wearing situation of longi鄄
tudinal and tie rod connector. Adjust
toe -in and dismantle hub according
to the formulation as well as lubricat鄄
ing hub gearing and adding lubrica鄄
tion.
3. When doing class -three mainte鄄
nance, disassemble to clean and
check it, then assemble it again .

荫

Use thrust plate to adjust steering

knuckle and front axle if the clear鄄
ance between them become wide,
keep the clearance less than 0.1mm.

荫

Replace king pin or bush if the

clearance between steering knuckle
king pin and bush reach 0.15mm.
Replace king pin if its diameter has
worn to 0.07mm.

荫

Replace ball pin or ball cup of

steering longitudinal rod have worn a
lot and the clearance can not be re鄄
moved.

荫

Replace hub oil seal if there is

damage and aging of cutting edge.

45

1. steering gear fuel inlet nipple
2. steering gear fuel outlet nipple
3. power-steering fuel return flexible pipe
4. power-steering flexible pipe assembly

5. power-steering oil container assembly
6. power-steering oil container supporter
7. oil pump outlet bolt
8. oil pump inlet nipple

9. oil pump inlet flexible pipe
10. hose clamp
11. wire clip

Steering system

The steering system of this series of
truck is power steering system.

Power steering system
It is composed of steering control
mechanism, transmission mecha鄄

nism, unitized power -steering gear,
power steering pump and power -
steering pipeline etc.

46

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

Power steering system adopts driv鄄
er's physical power and engine
power as steering energy. It can be
steering solely driven by driver if the
boost device do not work. So com鄄
pared with common mechanical
steering system, power-steering sys鄄
tem is acuter and safer, easing fa鄄
tigue of driver to a large extent.
Checking procedures of power -steer鄄
ing system's working state:
1. Put front wheel on the steering
platform.
2. Turn the steering wheel to left and
right pole to check if the steering
wheel has phenomenon of getting
stuck and getting impeded.
3. Check free play of steering wheel
when engine runs in idle speed. Free

play of steering wheel is 15-35mm.
Rotate adjusting screw clockwise to
decrease the free play, while rotate
anti-clockwise to increase it.
4. Rotational force of steering wheel
is around 19.6N when engine runs in
idle speed.
5. Check working condition of all of
the switches including starter switch,
rain wiper switch, exhaust brake
switch, horn switch and combination
switch.
Procedures of air exhausting in power
steering system:
1. Add steering oil (specified oil ) in鄄
to oil tank.
2. After standing up the front axle by
using jack, use prop stand to sup鄄
port frame.

3. Rotate steering wheel to left and
right pole for several times.
4. Check oil level of power-steering
oil tank, add steering oil if there is
not enough oil. Check whether oil lev鄄
el is in normal temperature scope.
5. Start engine, rotate steering wheel
to left and right pole for several times
if engine runs in idle speed. During
the process of exhausting air, add
steering oil constantly into oil tank to
ensure power-steering oil tank full.
6. Rotate steering wheel to make
wheel confront forward.
7. After switching off engine, check
oil level and add steering oil if neces鄄
sary.

47

Note: check whether steering oil is
in high temperature scope, if stee-

Check and maintenance:
1. Replace steering gear oil in time
and clean &replace filtering screen in
oil tank when a new truck runs for
3000 -4000km and runs every 5000
km afterwards.
2. Check oil volume and oil quality in
oil cylinder often, adding or replacing
if oil goes bad.
3. Pay attention to the mark of oil inlet
and outlet in pipeline connecting
when strip and re-assemble steering
mechanism to make sure it is con鄄
nected right. After connecting pipe-

line, check it to prevent air from enter鄄
ing into oil outlet pipeline of oil pump.
Start engine to make it run in idle
speed and add oil into oil tank. If the
system has not been poured enough
oil, rotate steering wheel repeatedly
left and right to extreme position and
add oil into oil tank at the same time
until oil level in oil tank doesn't drop
and has no air bubble. Add oil until oil
level is marked. When adding, check
oil tank and pipeline connector of
steering system to make sure them
clean, having no impurity. Specific
connect are as follows:

荫

Connect oil outlet to oil inlet of

steering oil pump.

荫

Connect oil return hole of steering

gear to oil return hole of oil tank.

4. When power -steering system
doesn't work, driver can use hand de鄄
pending on mechanical steering part.
However, using mechanical steering
only for a long time is forbidden.
5. Power -steering system has a
function of spot turn. Be sure to
avoid rotating steering wheel to ex鄄
treme position to prevent decreasing
life of components.
6. Add liquid oil according to pre鄄
scription. If surrounding temperature
is 0益 above, use L -HM464# anti鄄
wear hydraulic oil.If surrounding tem鄄
perature is 0益 below, use L-LM32#
antiwear hydraulic oil or 8# hydraulic
automatic steering oil. (mixture of
different oil type is forbidden). Use
DEXRON域type hydraulic oil for im鄄

48

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

ring oil has been cooled, check
whether it is at normal temperature.
If finding problem, repeat step4
and step5. If the problem still ex鄄
ists, repair power-steering pump.

49

port power -engine steering gear or
steering pump. ( referring to Ameri鄄
can General

Motors

Corporation

standard )
Using and maintenance:
1. Using of power -engine steering
system

荫

Rotating steering wheel to extreme

position for 5s is forbidden.

荫

Continuing rotating steering wheel

after rotating to dead space is forbid鄄
den.

荫

Rotating steering wheel when

wheels stand still is forbidden.

荫

Rotating steering wheel for more

than 90r/min is forbidden.
2. Maintenance of power -engine
steering system
Carry out principle of vehicle mainte鄄

nance that is " preventing mainly,
check and measure periodically and
maintain obligatorily ". Obey Ministry
of Communication standard JT/
T201-95
" Norm of vehicle maintenance craft "
and Ministry of city Construction
standard CJ17-86 " city bus repair in
technique condition ".

荫

Make inspection and adjustment

on steering system before driving,
during driving and after driving to
guarantee driving safety.

荫

Class-one maintenance ( 2000-

3000km)

因

Add lubrication periodically into every

lubricating point and add power-steering
oil in time when power -steering system
oil is not enough.

因

Make sure cross shaft and steering

cross and straight pull rod rotate flexible
and tight

因

Check the tightening condition of every

connection point to make sure them tight.

因

Check connection point of pipeline to

make sure there is no leakage.

荫

Class -two maintenance 渊10000要

15000km冤

因

Replace power-steering oil.

因

Clean filtering screen of power-steer鄄

ing oil tank.

因

Check slack of steering-wheel and ad鄄

just it to allowable value.

因

Make flaw detection on front shaft, ball

pin, steering knuckle , steering knuckle
arm, steering drop arm and steering gear
support frame.

因

Disassemble cross and straight pull

rod, clean and check each component to
make sure there is no crack on the body
of cross and straight pull rod as well as
making sure screw thread on two ends
not worn and limit wearing scope to 2mm
for cotter pin hole of cross and straight
pull rod , 0.5mm for spheri cal surface.
Also make sure spring can work well.

因

Referring to JT 辕 T 201要95 for oth er

non-mentioned part.

荫

For vehicle mounted steering drop

arm limit bolt :

因

Make sure limiting reliability

因

Do instant replacement if finding dam鄄

age on steering gear support frame
check arm.

因

Check connection bolt connecting

steering gear and support frame as well
as checking support frame and vehicle
frame to make sure them tight.

因

When doing left and right steering,

steering straight pull rod should not be in鄄
terfered in steering gear support frame
limit arm. If it results in the damage of
straight, replace it in time.

Braking system

Braking systems of trucks of this se鄄
ries are: parking brake system(center
drum) and running brake system (air
brake, hydraulic brake)

Running brake system

Air brake
1. Brief description of this system:
Compared with hydraulic brake, air
brake can bring greater braking
force under the condition that force
on the pedal is not great and the
pedal stroke is not long; at the same
time, dual-circuit air-pressure driv鄄
ing braking device is equipped to
front and rear wheel separately, so
the braking is safe, reliable, labor -
saving, and more effective; even if
one of the brakes does not work, the
vehicle can still brake safely.

50

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

Interface for air inlet

Interface for low fressure alarming

Interface for clutch booster

1.air compressor
2.front brake cha-mber
3.front cavity on main gas cylinder
4.rear cavity on main gas cylinder
5.safety valve

6.pressure control valve
7.barometer
8.brake valve
9.additional gas cylinder;
10.one-way valve

11.front quick-release valve
12.rear brake valve
13.rear quick-release valve

51

2. Structure and theory (referring to the following diagram).

Brake pipeline is arranged as fol鄄
lows: compressed air produced by
air compressor 1 comes into the
main air reservoir 3 (namely wet air
reservoir); and then the air is separat鄄
ed into two and come into the front
chamber 9 of the auxiliary air reser鄄
voir and the rear chamber 4 of the
main air reservoir, the front chamber
9 of the auxiliary air reservoir and the
rear chamber 4 of the main air
reservoir. Compressed air in the front
chamber 9 of the auxiliary air reser鄄
voir and the rear chamber 4 of the
main air reservoir come into upper
and lower chambers of brake valve
8, and then the air is transported
separately to rear brake chamber 12
and front brake chamber 2. Check

valves 10 installed on ends of the air
inlet pipes of the front chamber 9 of
the auxiliary air reservoir and the rear
chamber 4 of the main air reservoir in
case that compressed air in the air
reservoir flows backwards. There are
interfaces for air pressure gauge 7
and pressure -adjusting valve 6.
When air pressure reaches 0.74 -
0.84Mpa, compressed air props up
valve of the pressure -adjusting
valve, and comes into upper cover of
the air compressor to make air inlet
valve open and the air compressor
idles. When brake valve 8 is de鄄
pressed, front and rear brake cham鄄
ber 2 and 12 operate at the same
time, which makes front and rear
brakes operate. When the brake ped鄄

al is released, compressed air in
front and rear brake chambers go in鄄
to the atmosphere by front and rear
air-deflating valves 11 and 13.

52

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

1. return spring locating pin
2. roller shaft-brake shoe
3. roller-brake shoe
4. gripping ring -brake shoe roller
shaft
5/18. front brake shoe with liner as鄄
sembly
6/19. front brake friction plate
7. brake cam
8. front brake baseboard with liner
assembly
9. front brake dust cap

10. hex bolt
11. front brake air chamber support
frame with liner assembly
12. front left brake air chamber as鄄
sembly
13. hex bolt
14. front brake adjusting arm as鄄
sembly
15. shoe shaft fixed bolt
16. front brake shoe-shoe shaft;
17. front and rear brake shoe
shaft-liner; 18. return spring

Brake assembly
The function of brake is to utilize
power produced by friction between
brake drum and brake shoe slice to

absorb kinetic energy of vehicle to
decelerate or stop the vehicle. Front
and rear brakes of this brake system
adopt imbalanced structure and are

mainly composed of brake chamber,
brake arm and brake

53

54

Adjusting arm
1冤Lubrication: mount oil month on
adjusting arm, use lithium base
grease periodically to lubricate ad鄄
justing arm (maximum lubrication in鄄
terval is limited to 10000km), or else,
life of adjusting arm will decrease.
2冤Check adjusting arm's counter鄄
clockwise force moment periodically:
rotate adjusting nut of adjusting arm
counterclockwise when running every
20000km and measure whether the
rotary moment is bigger than 18Nm,
measure for three times repeatedly. If
the moment is smaller than 18Nm, it
indicates adjusting arm has been
damage and needs to be replaced
the adjusting arm assembly.

Brake
Front brake has the same structure
with the rear brake. It is shoe brake
with camshaft with fixed sustainer.
When braking, front and rear shoe
slices of the brake press to the rotat鄄
ing brake drum by the action of the
same push force; so the rear brake
shoe is called power-reducing brake
shoe. All above lead to imbalance of
forces that front and rear brake
shoes press on the brake drum, so
this kind of brake is called simple
imbalanced brake.
Clearance between friction disc of the
brake shoe and the brake drum must
be proper, before adjusting the
clearance, make the front wheel off
ground; adjusting steps are as follows:

Full adjustment
1. Loosening fixed nut of brake shoe
bearing pin and nut of binding bolt
on cam bracket.
2. Rotate brake shoe bearing pin so
as to make clearance between front
shoe and bearing pin end the same
as that between rear shoe and bear鄄
ing pin.
3. Start braking, make brake shoe
friction disc lean against brake drum
closely and brake camshaft auto鄄
matic positioned and tighten nut of
binding bolt on support frame.
4. Release braking and rotate worm
so as to make brake shoe friction disc
lean against brake drum closely. Then
counter-rotate worm, released by 3/4r,
brake drum should be rotate freely.

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

55

5. Test drive after adjustment, check
working condition of brake, whether
the brake drum get hot and whether
braking distance is proper. If not,
readjust it
Partial adjustment
Turn worm of the brake arm to adjust
clearance between friction disc at the
camshaft end of the brake assembly
and the brake drum. Adjusting meth鄄
ods are as follows: Face to the worm,
turn the worm clockwise, at the same
time, rotate the brake drum come -
and -go continuously till the brake
drum is suppressed completely, and
then return the worm anticlockwise
by 1/2 -3/4 circle, at this time, wind
age of the end of the brake drum
shaft is 0.25-0.4mm, while camshaft

end is 0.45mm.
Brake valve
Brake valve is a mechanism with
which the whole air brake system
controls the brake.
Using and Maintenance:
routine inspection
1. Before running, air pressure in the
pipeline should be checked, when
the air pressure is more than
0.6Mpa, the vehicle can start, and
the normal running air pressure is
0.74-0.84Mpa; if the air pressure is
lower than this value, check the air
pipeline for leak and check whether
the air compressor works normally.
2. Check working condition of the
brake in running whether there is any
trailing or the braking cannot return

and deal with the problems in time. If
the air pressure is lower than
0.45Mpa but the annuciator does not
warn, check the annuciator, replace
it if necessary.
3. If the brake shoe slice is damaged
or over worn, replace for new one;
surface of the new liner should be
grinded, and there should be no oil
dirt, scratches, chap on the surface.
Friction disc must be made of the
same material.
4. Replacing friction disc or rein鄄
stalling shoe slice shaft and brake
camshaft will damage contact condi鄄
tion between former friction disc and
brake drum, because of which, full
adjustment must be done. (see de鄄
tailed adjusting methods above)

Periodical inspection
1. Class -one inspection (1500 -
2000km)

荫

Exclude oil water in air-reservoir

荫

Fill lubrication into position that

needs lubrication.

荫

Check and adjust loosening and

tightening degree of air compressor.
2. Class -two inspection (10000 -
12000km)

荫

Disassemble and adjust brake as

well as adjusting clearance between
brake shoe friction disc and brake
drum.

荫

Check working condition of air

conditioner compressor and clean air
outlet valve clud away.

荫

Disassemble and check brake

chamber rubber film and replace it if

necessary.
3. Class -three inspection (24000要
30000km)

荫

Disassemble and adjust brake

valve and check brake chamber rub鄄
ber film, replace it if necessary.

荫

Check brake and brake pipeline,

replace it if necessary.

荫

Clean all of the pipelines to ensure

pipeline unblocked.
Hydraulic brake
1. Brief description of this system:
Hydraulic brake , which is composed
of vacuum booster, vacuum tube,
brake master cylinder brake pipeline
front and rear brake , is safe, labor-
saving and sensitive.
When depressing running brake ped鄄
al, the reason why the braking is

non-effective is likely that there is air
in system without lacking of braking
oil袁 follow the following steps to re鄄
lease air: right rear wheel brake-left
rear brake-right front brake-left front
brake. Follow air outlet methods be鄄
low:

荫

Clean air -drain screw of main

cylinder and wheel cylinder.

荫

Remove oil -drain plug of main

cylinder or reservoir and fill it with
brake fluid until lever reach the edge.

荫

Depress the brake pedal several

times before holding it depressed
and release the air drain screw to
bleed. Repeat doing this until air in
tube be bled completely. Keep a little
oil left, or air can reenter the system.

荫

Fill reservoir with brake fluid.

56

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

2. Note for using brake fluid

荫

The specified brake fluid of this

series of truck is synthetic brake fluid
of class JG3(GB10830).
Never use mixed brake fluid.

荫

Synthetic brake fluid is good at

sopping up. They should be stored
in a clean sealed dry container, keep
away from water, organic solvent,
petroleum, and dust. Otherwise the
vehicle's capability of brake would
be cut down seriously.

荫

Clean system with alcohol before

replacing brake fluid with different
brand . Follow these if alcohol is un鄄
available.

因

After draining all old brake fluid , fill

reservoir with new fluid near to the open鄄
ing and bleed system again to sweep old

1. brake pedal
2. vacuum booster and main
cylinder assembly
3. reservoir

4. connection cylinder
5. rear brake
6. vacuum cylinder
7. intake manifold

8. front brake
9. vacuum check valve
10. connect to vacuum -
alarm

57

fluid away.

因

Fill system with brake fluid.

因

Brake pedal's free play should be 5 -

8mm after adjusted, or it will cause main
booster work abnormally and make brake
drum over hot.
3. Running brake system

荫

Brief description of this system:

The running brake is hydraulic drum,
both front and tear are two leading
shoe brake . It is composed of bot鄄
tom plate, wheel cylinder, brake shoe
set with pad, and return spring set.

荫

Adjustment of running brake

The clearance between pad and
drum will be bigger and bigger due
to wear. In order to ensure brake
work well, adjust it regularly following
these steps.

Jack up the wheel which you want to
adjust and remove the seal plug. Dial
the adjusting gear of wheel cylinder
piston along the direction of arrow
near the adjusting hole on bottom
plate with special adjusting screw
and at the same time rotate the
brake drum until the drum not rotated
by hands. Then rotate the adjusting
gear back for 5 -9 teeth, keep the
pad 0.2 -0.45mm away from the
drum, so that the drum can rotate
freely again .

荫

Use & Check

Replace the pad which is worn out or
damaged. Before installed, the new
pad should be ground. Make sure that
the new pad has not oil coat, also has
not crack and chap and other flaw.

The clearance should be adjusted in
every time of maintenance . Check
drums with hands for temperature ev鄄
ery time you park, adjust the clear鄄
ance if the temperature is too high .
Check wheel cylinders for leakage ,
and replace leather gasket if leakage
is detected. Protect drums from be鄄
ing wrong result from over heat and
other reasons.
4. Vacuum booster

荫

Brief description of this system:

Booster of this series of truck is dual
diaphragm vacuum booster, which is
composed of return spring, control
valve, rubber diaphragm, noise elim鄄
ination board, and so on .

荫

Adjustment

Booster has been adjusted in factory,

58

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

1. parking brake drum
2. parking brake shoe with friction
disc assembly
3. parking brake adjusting bolt
assembly
4. parking brake shoe bottom
end drag spring

5. parking brake shoe compres鄄
sion spring;
6. parking brake shoe push rod
7. brake shoe seat
8. brake shoe compression
spring push rod
9. adjusting window lid

10. parking brake backing plate
assembly
11. parking brake shoe rocker
arm assembly
12. parking brake drag spring
13. parking brake shoe drag
spring
14. parking brake push rod sup鄄
port spring
15. card
16. grommet

don't disassemble it and protect the
diaphragm from being been dam鄄
aged.
Parking brake system
Brief description of structure:
Parking brake system is composed
of parking brake, control cable as鄄
sembly and control handle. Parking
brake is a brake of center-drum type
(picture below) that is mounted on
rear side of the transmission, acts on
the drive shaft and is mainly used in
parking as well as in emergency
working with foot brake. Control han鄄
dle and parking brake pull arm are
connected by flexible shaft.

59

Adjustment
Clearance between parking brake
drum and friction disc is 0.65mm,
and the upper clearance is as same
as the lower clearance. Because of
friction disc wearing, this clearance
must be adjusted in time. The steps
of adjusting are shown as follows:
1. Jack up the rear axle to make one
wheel off ground.
2. Put the parking brake handle to
the lowest position, and shift the gear
to neutral position.
3. Turn the small hole on the brake
drum to the lowest side, put a screw鄄
driver into the hole and toggle the
gear-type adjusting bolt till the brake
drum can be stopped completely,
and then return the adjusting bolt by

2-6 teeth.
If adjusting above is executed cor鄄
rectly, when the parking brake is
tensed, the vehicle can be stopped
on a 20% ramp.
Using and maintenance
1. Check and adjust clearance be鄄
tween the brake and the brake shoe
slice regularly.
2. When doing class -two mainte鄄
nance, disassemble brake to check
wearing condition of brake lining . If
thickness of gasket has been worn
down by 2mm below ,
Disassemble the gasket and re鄄
assemble it. Gasket gluing intensity:
when boosting transversely , boost鄄
ing by 2.94mpa under normal atmo鄄
spheric temperature is not allowed to

dropped. Glued gasket should be
rubbing processed. Size (after rub鄄
bing processed): R94.5依0.15mm遥

60

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

Wheel and spare wheel riser

Wheel

Brief description
Every truck has seven wheels in all,
one of which is spare wheel.
Using and maintenance
In order to use for a longer time,
please charge tire according to
specified pressure valve. Never drive
when pressure is insufficient. It is
normal that pressure increases dur鄄
ing travel, and do not try to reduce it
by deflating. Check the tire pressure
when tire is not hot. If the two central
patterns on tire tread touch against
ground under fully loaded, the pres鄄
sure is normal.
Clean the rust and other dirty on rim
before installed. It should be talked

on the surface between inner tube
and outer tire. Wheel nuts should be
tightened with two steps. Tighten all
of them firstly before tightening them
with specified torque according to
diagonal sequence.
Check wheel nuts regularly, and
retighten them with torque if loosen鄄
ing is detected.
Transposition of tires should be done
in class-three maintenance to ensure
even wearing. Tires are usually
changed with each other acrossed.

Spare wheel riser regulator

Description of structure and using
Spare wheel riser is driven by cate鄄
nary's suspension internal geared
wheel. It is mounted underneath the
frame. To operate it , fix it on the
frame and tighten it with hand before
rocking back for 15 degree. (As
shown in the left picture below)

1. Spare wheel cross鄄
beam support frame
2. Spare wheel regula鄄
tor shell assembly

3. Spare wheel carrier
frame assembly
4. supporting sleeve
5. connecting rod as鄄
sembly

61

Maintenance of spare wheel regulator
Check whether the spare tire is loose
and whether chain and wheel brack鄄
et spring rupture before everyday us鄄
ing; if there is anything wrong, re鄄
place it immediately. Lubrication
should be applied to the driving
parts of the riser in case of rust and
for convenient rising.
Disassemble spare wheel riser when
doing class -three maintenance.
Check, clean and replace compo鄄
nents if they have been worn greatly.

62

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

Electrical equipment

63

64

1. chassis cable harness assembly
2. start/choke controller
3. electric horn device
4. generator

5. water temperature sensor
6. oil pressure sensor
7. engine earth cable
8. backgear earth cable

9. starter
10. fuel gauge sensor
11. low air pressure alarm device
12. battery

General: schematic diagram of cha-ssis electrical equipment

OWNER爷S MANUAL for

HFC1061,HFC1063,HFC1083

series trucks

65

Starter

Generator and Regulator

Lighting device.

Headlight
This series of truck have two head鄄
lights which are embedded in front of
cab symmetrically. The headlight
called double filament bulb with two
different pieces of filament and can
shine two different kinds of ray, the
brighter one is used as high light

while the dimmer one is used as low
light. If running at night, turn on the
high light to lighten the road, and
switch to low light when two vehicles
pass each other to avoid dazzling
your eyes.

In order to lighten road clearly with
headlight, adjusting stripping and

old

pa

tte

rn

ne

w

pa

tte

rn

Note:

荫

Generator should be connected

with regulator correctly and reliably,
and the polarities of generator and

regulator should be matched prop鄄
erly.

荫

Never check generator by

short-circuit fire wire and magnet鄄
ic field.

荫

The diode and insulation of

generator can be inspected with
multi -meter and ohmmeter. Don't
use megohmmeter and AC power
to inspect to avoid burning diode.

Note:

荫

Starter should be connected

with battery correctly.

荫

Every time starting, don't keep

starter working continuously for
more than 15s and stop for 1 -2
seconds in the interval, since over
hot may damage it. Rest it before
trying to start it again.

荫

After several continuative fail鄄

ures of start, check starter,
solenoid switch, battery, wires as
well as oil supply system. Retry af鄄
ter the trouble shooting.