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Project: N125

Brake System Service Manual

Number: W5000-NAM-PV-DP-G9-16

Version: 1.0

Compilation:

Proofread:

Review:

Standardization:

Countersignature:

Approval:

ANHUI JIANGHUAI AUTOMOBILE CO., LTD.

Year Month Day

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Foreword

《

The Light Cargo Truck Service Manual-HFC1036K

》

describes the

precautions that you must pay attention to, when testing HFC1036K Series

models, doing maintenance,repairing, as well as disassembling and assembling

the parts. Meanwhile, it introduces the basic judgment methods and solutions to

some of the common problems for the vehicles.

All the information involved in the Service Manual should take the latest

data and the latest status of the vehicle when it is published, as a reference.

However, with the advances in technology, the product updates, and other

reasons, all the content in the Service Manual might change.Our company

reserve the rights to change this manual without prior notice.Thanks for your

understanding.

《 The Light Cargo Truck Service Manual-HFC1036K 》 is projected by Anhui Jianghuai

Automobile Co., Ltd, and complied by Commercial Vehicle Research Institute.

The right of interpretation for all the provisions in the Service Manual shall be

vested in Anhui Jianghuai Automobile Co., Ltd.

Anhui Jianghuai Automobile Co., Ltd.

March, 2014

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Contents

Brake and Operation System

1. Overview ………………………………………………………………………1

2. Main Data and Specification of Front and Rear

Brake ……………………………………………1

3. Brake System Inspection and

Maintenance……………………………………………………3

4. Fault Handling for Brake

System ………………………………………………………13

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1. Overview

The truck adopts a II-dual-circuit hydraulic brake system, the front brake is a hollow disc brake, the rear

brake is a bi-directional drum brake, the vacuum booster is a non-cross-cutting, double-diaphragm structure. The

brake master c ylinder structure is a single center valve. It equipped with LSPV (loading sensing pressure

proportioning valve)--an adjustable Brake Force Distribution. The front brake includes brake caliper, brake discs,

fender, etc., rear brake includes brake drum, brake plate, brake shoes, paddle, the parking brake pulling plate.

The park brake is manual control mechanical ratchet cable type, acting on the rear brake.

Front brake device Rear brake device

2.Themaindataandspecifications of front and rear brakes

Front brake Rear brake

Type Disk brake Type Drum brake

Brake disc

diameter

(mm)

274 Brake drum

diameter(mm)

220

Brake disc

thickness(mm)

26 Brake drum idth

(mm)

Brake wheel cylinder 2×46 Brake wheel cylinder 17.46

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diameter(mm) diameter(mm)

Friction disks,

clearance (

mm)

0.3～0.5 Clearance between

friction blades(mm)

0.3～0.5

Friction blades

thickness

(mm)

11 Friction blades

thickness (mm)

4.7

Brake pedal free

stroke

(mm)

3～8

3. Brake system inspection and maintenance

Front brake disassembly:

1) Brake caliper disassembly:

① disassemble the two bolts installed on the steering

knuckle, and remove the brake caliper.

② Remove the friction blades from the brake caliper,

and check the thickness of it.

Standard thickness: 11mm；

Wear limit thickness: 2mm

2) Brake disc disassemble:

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① disassemble the five nuts on the brake disc in

sequence, and take out the brake disc.

② Visual inspection: Check that if there is any

uneven abrasion, crack or serious damage on the surface of

the brake disc. If so, replace it.

③ Runout Check: Use dial indicator to check runout;

Runout limit: 0.05 MM (can be measured in the inside

edge, 10mm to the brake, if runout exceeds the set value,

replace it or carry out the necessary process.

④ Thickness Check: Use dial indicator to check the

brake discs' thickness. If thickness is less than wear limit,

replace brake discs.

Standard thickness: 26 mm; wear limit: 24 mm.

3) Fender disassembly:

① Disassemble three mounting screws which are

installed on the steering, and remove the fender

② Visual inspection: Check the fender whether there

had been a serious distortion, and if so, please replace it

Front brake installation:

The install order of the front brake is in reverse with the disassembly order.

Brake caliper mounting bolt tightening torque: 140～180N·m

Brake discs mounting nut tightening torque: 45～52N·m

Front Brake running-in procedure:

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Repair or replace brake discs、if there appears brake pedal soft when running in a short distance, please

replace friction plates, and please operate as the following steps to run-in the joint surface between brake plates

and discs.

Note: Before running in, if the braking effect is not so good, please control the speed. Only under the

security road and traffic conditions, this step can be performed, it is necessary to pay attention to safety.

1) Drive the car on a straight road.

2) Control the brake pedal, to make the vehicle brake in 3～5 seconds.

3) After driving a car for a certain distance, park the car for 3 minutes to cool the brake s ystem.

4) Repeat the steps 1～3, until the friction plates and brake discs fully run-in.

Rear brake disassembly:

1) Brake drum disassembly:

① Brake drum and rear wheels use the mounting nuts

in common, and remove the rear wheels firstly before

disassembling the brake drum, then remove the brake

drum.

② Check the inner diameter of brake drum: because

when the worn or abrasive lead to the size increase,

please change the brake drum, or adopts the friction

plates whose size has been increased.

Standard ID (inner diameter): 220

Wear Limit: 221.5

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2) Rear brake assembly and disassembly:

① Disassemble four nuts installed on the rear axle

flange, then remove the rear brake.

②Visual inspection: Check the pump inside the brake

whether exists leaks or damage.If so, replace the entire rear

brake assembly; check the brake plate assembly whether

deformed or cracked.If so, replace the entire rear brake

assembly; check if the other parts existing any unusual

deformation and wear. If so, replace the parts.

3) Brake shoes disassembly

① Remove the two back springs respectively, then

release the springs.

②Disassemble the two pressure s pring seat

③Disassemble the clearance adjustment assembly and

the drop-down spring

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④ disassemble the guide plate and return spring of the

brake foot, and then you can remove the brake leading and

sub-foot.

⑤ Check the friction plates for abnormal wear, if the

abnormal wear exists, please replace brake shoes and

friction plates assembly.

Friction plate s thickness: 4.7mm

Limit thickness: 1mm

Rear brake installation:

The installation order of rear brake assembly and parts reverse with the disassembly order

Rear brake assembly mounting nuts tightening torque: 25～30N·m

Note: ①When installing the rear brake assembly nuts tighten them according to the diagonal order.

② When installing brake drum, please adjust clearance between it and the friction plates, the

clearance is 0.3～0.5mm.

Brake Line device disassembly

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1) Brake lines diagram

1. Oil reservoir jug 2. Vacuum booster with brake master cylinder 3. Single pass connector 4. Cross 5. Front

brake wheel cylinder 6. Vacuum Cylinder 7. Vacuum pump 8. LSPV( loading sensing pressure

proportioning valve) 9. T-Cock 10. Rear brake wheel cylinder

2) Oil reservoir jug disassembly and inspection

The following picture shows the location of the oil

reservoir jug on the vehicle.

(The brake fluid can only use liquid brake fluid and

must be in consistent with 1703 DOT value, the

corresponding GB 10830 JG4）

① Disconnect two hoses connected with the oil

reservoir jug, and remove the two mounting

screws of the oil reservoir jug, then take out the

oil reservoir jug.

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②Vehicle check: Check the height of the brake fluid

level, to confirm if brake fluid level in the oil reservoir

jug is within the specified range (between MIN and

MAX).

If the level is too low, please check whether the oil

reservoir jug and brake system existing leak.

3) Disassembly of vacuum booster with brake

master cylinder

① Disconnect the tube and hose connecting with the

brake master cylinder.

②Disassemble the locking pin and washers from the

brake pedal.

③ Remove the four mounting nuts installed on the

brake clutch pedal, and remove the vacuum booster with

brake master cylinder.

4)Brake pedal disassembly and inspection

①Brake pedal and clutch pedal integrated in the brake

clutch pedal assembly,

the pedal repair need to replace the entire brake clutch

pedal assembly. Assembly remove refer to the disassembly

method of brake clutch pedal assembly.

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② Check non-slip rubber foot pads of brake pedal for

excessive wear or damage, and if so, please replace

non-slip rubber feet.

5) Disassembly of LSPV (loading sensing

pressure proportioning valve)

① Disconnect three tubes connected with LSPV, then

remove

② a nut connecting with the rear axle bracket, and

then remove the two bolts fixed on the frame.

Brake Lines device installation

The installed order of all parts and components is in reverse order of removal.

Vacuum booster with brake master cylinder mounting torque: 24～30N·m

LSPV mounting torque: 20～25N·m

The brake pipe connector torque: 16～20N·m

Brake lines disassembly and installation precautions

1) All brake lines can not be excessively bent, twisted and stretched.

2) Confirm that all brake lines will not be interfered with other parts when the vehicle is stationary or

steering.

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3) Brake lin es are the important security components, if finding that brake fluid leak, please tighten the fixed

device. If you find damaged parts, please replace the new applicable components.

4) When you disconnect brake lines, please seal the connector end to avoid dust and dirt.

5) Refill the brake fluid (brake fluid model DOT 3/DOT4) after disassembling and installing, and then bleed

air

Brake Lines air emissions methods and steps

1) Continuously depress the brake pedal, and set up the pressure within the brake system.

2) After reinsert the air hose (hose connected to the recycling containers, so as to avoid the brake fluid

flowing out pollute other parts), depress the pedals and hold it, not release.Open the exhaust bolts on the caliper o r

brake cylinder, and close the exhaust bolts, after the brake fluid which containing air bubbles is no longer flowing

out from the exhaust vent.

3) Repeat the above two steps until the brake fluid overflow from the exhaust hoses does not contain air

bubbles.

4) Note: This is only possible when the engine is started, you can operate the exhaust work for the s ystem.

The parking brake device disassembly

1) The parking brake device breakdown drawing

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1. parking handle 2. front drawbench 3. park connector 4. left drawbench 5. left park drawing-bracket 6. right

park drawing-bracket 7. right drawbench

2) Parking handles disassembly

Firstly, to remove the retaining nut and adjusting nut

of the front drawbench at the end of the handle, loosen the

front drawbench, and then disassemble the handle

mounting bolts and nuts, lastly remove handle.

3) Parking drawbench disassembly

① In accordance with the installation point of the

drawbench, disassemble the mounting bolts or screws in

sequence.

②Vehicle check: Check the parking brake drawbench

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fot distortion, or worn, cracked, if it has, replace it.

4) Parking connector disassembly

1 Remove the connectors of the three drawbenches,

release the spring, and then remove the lockpin, and

remove the two pin rolls, finally remove the parking

connector assembly.

The parking brake device installation

The installation order of the parking brake is in reverse to the disassembly order.

Parking handle mounting bolts torque: 23 N•m～27 N•m

Parking handle mounting nuts torque: 23 N•m～27 N•m

Note: When checking the brake system, the vehicle should be placed on level ground, and use the corner

blocks to fix wheels.

Parking brake device adjustment

1)When the parking handle is in a put-down state, and having installed the repair/replacement parts, please

adjust the right parking drawbench length to ensure the installation status.

2) After debugging is completed, pull the parking handle with 210N power whose direction is vertical to the

handle.adjust the front parking drawbench, to lock the handle on 5 - 7 gears, and then use the two ends left-turn

and right-turn muts to lock them.

5. Brake system fault handing

Service braking system troubleshooting:

Common troubleshooting table

Fault phenomenon Possible cause Solution

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When braking,the

vehicle ran off

Left and right tire under-inflation Adjustment

Front wheel adjustment is not correct Adjustment

Brake shoes poor contact Adjustment

Brake Shoe surface is with grease or oil Replacement

Incorrect installat ion brake cylinder Adjustment

Self-regulating bodies have faulty Adjustment

Insufficient braking

force

Brake fluid is less or polluted Supplement or

replace

Air in the brake system Bleed the s ystem

Brake vacuum booster has faulty Replacement

Brake shoes poor contact Adjustment

Brake Shoe surface is with grease or oil Replacement

Brake Shoes dragging leads to the brake rotating parts

overheating

Adjustment

Pedal stroke

increases(pedal to the

floor distance

reduction)

Air in the brake system Bleed the s ystem

Brake fluid leaks Adjustment

Self-regulating bodies have faulty Adjustment

Brake retard

The parking brake is not fully liberalized Release

The parking brake is maladjusted

Brake pedal return spring wears Replacement

Brake master pump no-return valve or piston return

springs have defective

Replacement

Clearance between push rods and brake master cylinder

is too small

Adjustment

The parking brake

function is not

Rear brake shoes are damaged Replacement

Rear brake shoe surface is with grease or oil Replacement

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enough The parking brake handle stroke is too large Adjustment

Self-regulating bodies have faulty Adjustment

Parts troubleshooting:

Brake shoes:

Fault problems Possible reasons Handling method

The middle part

of brake foots

poor contact

1. The inner cavity of brake drum is deformed. 2.

Brake Plate damage. 3. Brake shoes bent. 4. Brake

shoes pin or bushes are worn. 5. The bearing of wheel

hub is loose.

Repair or replace

as needed.

Within a brake,

inside foots wear

is uneven

1. The installation of brake shoes is imbalance

2. Brake shoes pin or bushes are worn.

Repair or replace

as needed.

The wear amount

of the ends of the

brake shoes is

large.

1. Brake plate is deformed.

2. Brake shoes pin or bushes are worn.

Repair or replace

as needed.

The surface of

brake linings is

glazing.

1. The surface of brake linings is polluted by the

lubricating oil. 2. During the maintenance process, the

model of the brake linings is incorrect.

Repair or replace

as needed.

The surface of

brake linings has

scratches.

1. The friction surface of brake drum is uneven. 2.

There are foreign materials in the brake drum.

Repair or replace

as needed.

Edge wear of

brake linings

1. The width of break linings is not correct. 2. The

bearing of wheel hub is loose. 3. Brake shoes bent.

Repair or replace

as needed.

Brake drum:

Fault Possible reasons Handling method

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problems

Part of brake

drum is at

high

temperature

1. Brake drum is out-of-round. 2. The installation

of brake drum is in different heart.

3. The bearing of wheel hub is loose.

Repair or replace as

needed.

The whole

brake drum is

at high

temperature

1. The friction material on brake linings or brake

drum deteriorated.

2. Brake overburden. 3. Drive overburden, wheel

hub bearing is at high temperature.

Repair or replace as

needed.

The brake

drum has

scratches

1. The friction material on brake linings or brake

drum deteriorated.

2. Brake overburden. 3. There are foreign matters

among brake lining or brake drum.

Repair or replace as

needed.

Brake drum

cracks

1. Drive overburden 2. The friction material on

brake linings or brake drum deteriorated. 3. Brake

overburden.

Repair or replace as

needed.

Park system troubleshooting

1) Trouble lamp is lit or not lit.

①check to see if the trouble lamp is damaged in its performance

②check to see if there is loose between the trouble lamp and the screw connection of the toothed plate

Maintenance:

If the above situations exist, replace or reinstall the trouble lamp.

2) The braking force is not enough or fails:

①check to see if the drawbench plate is connected with the brake drawbench

②check to see if the locknut for sliding

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③check to see if the current braking distance and the braking distance that the vehicles required is the same

Maintenance:

①The first case: please connect the drawbench plate and brake drawbench.

②The second case: please replace the locknut.

③The third case: please adjust the distance of the locknut.