Great Wall Socool (2006 year). Instruction - part 14

 

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Great Wall Socool (2006 year). Instruction - part 14

 

 

BR-3

 Troubleshooting (continued)

Braking System

Notice and Troubleshooting

Trouble

Causes

Inspection items

There is clatter noise when using

the brake

(Drum-type brake)

The brake shoe is seized on the flange of rear baffle;

The flange of rear baffle is worn;

The pressure spring of brake shoe is loose or missing;

The fixed bolts of brake bottom plate is loose;

(disc type brake)

The brake pad support plate is loose or missing

The mounting bolts are loose;

Add lubricant

Change the lubricating flange

Change

Tightening it

Change

Tightening it

There is hoarse noise or quack-

quack when using the brake

The brake shoe or brake pad is worn;

The brake caliper, the wheel or the rotator interferes each

other.

There is friction between the dust cover and brake disc,

the brake bottom plate and the brake drum;

The other braking part has trouble

There is friction between the tire and body

Change the part, and re-process

precisely the brake drum or

rotator if the abrasion is serious;

Make change according to real

situation;

repair or change

Make repairing according to

real situation;

Change

Check or maintain the part

T h e r e   i s   s u c h   n o i s e   a s

continuous screaming, quack-

quack, oscillating sound, etc.

Notice: the braking materials

may generate the natural noise

and heat during friction, and

thus emit the energy. Therefore,

i t   i s   n o r m a l   t o   h a v e   t h e

s c r e a m i n g   n o i s e .   T h e s e

phenomena will be more serious

under the condition of frigidity,

torridity, and over humidity,

s n o w i n g   a n d   m u d .   t h e

screaming noise occurring

occasionally will not lead the

fatal brake trouble nor reduce

the effective properties of the

brake.

The brake drum, brake liner, liner or brake pad is worn

or scraped

The brake liner or brake pad is dirty or with oil stain or

polished.

The brake liner or brake pad is improperly used.

The brake pedal or vacuum booster drag rod is unsuitably

adjusted.

(disc type brake)

The brake pad silent pad is loss or damaged;

The brake pad is worn to the degree that the abrasion-

indicating lamp of brake pad has friction with the rotator.

There is burr or rust on the brake caliper.

(Drum type brake)

The pressure spring of brake shoe is soft in rigidity, or is

damaged or unsuitable.

The pressure spring pin or spring of brake shoe is loose

or damaged;

There is crack on the brake bottom plate flange

Check, repair or change

Clean or change

Check or change

Check for adjustment

Change

Change

Clean or polish the burr

Check, repair or change

Check, repair or change

Check, repair or change

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BR-4

Braking System

Notice and Troubleshooting

Troubleshooting (continued)

Trouble

  Causes

 Inspection items

There are quack-

q u a c k   n o i s e s

without using the

brake.

Alien materials such as stone is reeled inside the wheel shell

Nuts on hub is loose;

The brake pedal or vacuum booster pushrod is adjusted

improperly;

The wheel bearing is worn or damaged or lubricated

insufficiently;

(disc type brake)

The outer end edge of brake pad support plate or brake pad

is dog-eared;

The silent pad is poor in properties;

The sliding liner is worn;

The mounting bolt is loose

The piston returns incompletely

(drum type brake)

There is loose or redundant part.

Clear away the alien materials

Tighten the nut to the specified torque; and

change it in case the bolt hole is enlarged;

Check and adjust

Check, lubricate or change

Check repair or change

Check and make change according to real

situation

Check and make change according to real

situation

Check and tighten according to the necessity.

Check, repair or change

Check, take out or repair.

There is continuous

screaming noise

without using brake

The brake pedal or vacuum booster pushrod is adjusted

improperly

The vacuum booster, master cylinder or wheel-brake cylinder

returns incompletely.

(Disc type brake)

The piston is rusted or seized;

The brake pad in brake caliper locates improperly;

There is friction between the brake disc and brake caliper

shell;

The brake pad support plate is mounted improperly;

There is interference between the abrasion indicating lamp

of brake pad and the brake disc due to the brake pad

abrasion;

(Drum type brake)

The pressure spring of brake shoe is soft rigidity, damaged

or unsuitable;

There is crack on the brake bottom plate flange;

There is interference of brake bottom plate with the brake

drum after it is bending or warping.

The brake drum interferes with the brake bottom plate or

with brake shoe due to it is processed improperly;

Other brake parts



There is loose or redundant part in braking system;

The brake liner is polished due to it is adjusted over-tightly;

The wheel bearing is worn, damaged or lubricated

insufficiently.

Check and adjust

Check, repair or change

Check and add the lubricant according to

the necessity;

Repair or change

Repair or change

Repair or change

Change

Change

Repair or change

Repair or change

Change the brake drum

Check, maintain and change according to

the necessity;

Check, maintain and change according to

the necessity;

Check, maintain and change according to

the necessity;

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BR-5

Braking System 

Inspection and Adjustment

pedal push rod

braking lamp switch

pedal push-rod

free stroke of

pedal: (3-6) mm

Inspection and adjustment

Inspection on and adjustment of brake pedal

1.

Check the pedal height as shown in the drawing to

whether it is correct,

The height from the pedal to the front floor:

Dr SF

160mm

SL SK  SY  SJ 

(190-200)mm

2.

Adjust the pedal height if necessary:

(a)

Loosen the locking nuts of braking lamp switch;

(b)

Loosen the braking lamp switch to the most degree.

(c)

Loosen the locking nuts of drag rod;

(d)

Adjust the pedal height through rotating the pedal drag

rod;

(e)

Rotate the stop light switch reversibly until it contact

with the stop baffle of pedal.

(f)

Screw up the two locking nuts.

(g)

Check the braking lamp is lightened or not when tread

down the brake pedal.

(h)

Check and adjust the pedal free stroke after adjusting the

pedal height

QK Adjust the free stroke of pedal if necessary:

(a)

Loosen the locking nuts of the pedal drag rod and rotate

the pedal drag rod to adjust the pedal free stroke.

(b)

Start the engine to confirm the free stroke.

(c)

Check the pedal height after adjusting the pedal free

stroke.

3.

Inspection on Pedal Free Stroke:

(a)

Stop the engine working and tread down the brake pedal

several times until the vacuum booster is not in the stage

of vacuum.

(b)

Tread down the pedal until the resistance occurs, and

measure the distance shown in the drawing.

Pedal free stroke

(3-6)mm

pedal height

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BR-6

Operation test of vacuum booster

Remark: check the operation of vacuum booster with the

vacuum booster tester if workable.

1.Operation inspection

(a)

Before starting the engine, tread down the brake pedal

several times, and check the pedal reservation distance to

ensure there is no change occurs.

(b)

Tread down the brake pedal and start the engine. If the

treaded pedals continue to move downward, which means

the operation is normal.

1.

Inspection on Air-tight

(a)

Start the engine for 1-2 min and then turn it off. Then

tread down the brake pedal slowly for several times, if the

pedal move downward continuously in the first, but

return gradually in the second or third time, which means

the vacuum booster has a good air-tight.

(b)

Tread down the brake pedal when the engine is working,

then stop the engine, but tread the pedal down. If the

reservation distance doesnít change within the 30 seconds,

which shows the air tight of vacuum booster is good.

Air-bleeding of braking system

Remark: air-bleeding is required if any operation for braking

system is conducted or the pipe line is doubted to have air.

1.

Fill the oil cup with the brake liquid

Check the liquid level of oil cup after the air in each wheel

brake pump is exhausted. If necessary, add the brake liquid.

2.

Connect the vinyl resin pipe with the vent screws.

Insert the other end of pipe into the container with half brake

liquid.

Remark: the air-bleeding shall begin from the longest pipe line

when the wheel-brake cylinder is exhausting the air.

3.

Air exhaust of the pipe line in braking system

(a)

Tread down brake pedal slowly several times.

(b)

Loosen the vent screws until the brake liquid flows out

while letting the assistant tread down the pedal. Then

screw up the vent screws.

(c)

Repeat this approach until there is no air in the liquid.

4.

Repeat the approach for the wheel-brake cylinder.

normal

abnormal

the third time

the second time

the first time

Braking System 

Inspection and Adjustment

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-7

Check and adjust the parking brake

1.

Check the stroke of operating lever of the parking

brake to see whether it is correct.

Drag the brake operating lever to the max stroke and count the

grooves it passes.

Stroke of operating lever of parking brake:

Dr

(9-10) Teeth

SL SK SY

(7-9) Teeth

2.

Adjust the parking brake lever where necessary:

Remark: Adjust the rear brake shoe clearance before the

adjustment.

Brake shoe clearance: 0.6mm

(a)

Loosen the locking nut and then rotate the adjustable nut

until the stroke is correct, then screw up the nuts.

(b)

The brake shoe shall not be stagnant after the adjustment.

Braking System

Inspection and Adjustment

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BR-8

Braking System

Master Cylinder

Master Cylinder

Disassembly of Master Cylinder

1.

Tear down the alarm joint for liquid level;

2.

Exhaust the brake liquid with the injector:

Notice: brake liquid must not be left on the paint surface,

if any, clear it away.

3.

Tear down the pipeline of braking system;

Tear down the pipeline of braking system from the master

cylinder with SST.

4.

Take apart the master cylinder:

(a)

Tear down the four nuts and the three-way joint.

(b)

Tear down the master cylinder and sealing washer from

the vacuum booster

cup cap

filtering screen

oil cup

vacuum booster assembly

sealing liner

master cylinder body

front three-way valve

SST

SST

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BR-9

Braking System

Master Cylinder

Mount of Master Cylinder

1.

Adjust the length of vacuum booster pushrod before

mounting the master cylinder;

2.

Mount the master cylinder:

Mount the master and sealing washer on the vacuum booster

with four nuts.

3.

Connect the two pipelines of braking system;

Mount the brake pipeline on the master cylinder with SST and

screw up the nuts.

Fastening torque



Dr SF

(18 2)Nm

SL SK SY SJ

(19 1)Nm

4.

Connect the alarm switch joint for liquid level;

5.

Fill the oil cup with brake liquid and exhaust the air in

the brake pipeline;

6.

Check to see whether there is brake liquid leakage;

7.

Check and adjust the brake pedal.

SST

SST

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-10

Brake System

 Vacuum Booster

Vacuum booster

Disassembly of Vacuum Booster

1.

Take apart the master cylinder

2.

Tear down the vacuum hose from the vacuum booster

3.

Tear down the return spring

4.

Tear down the clamping pin and U-shaped clamping pin

5.

Tear down the vacuum booster, sealing washer and U-

shaped clamping head

U-shaped clip head

shock pad

adjusting shim

shock pad

vacuum booster

front three-way valve

master cylinder body

bracket

one-way valve

sealing liner

Disassembly of Vacuum Booster

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-11

Brake System

Vacuum Booster

Inspection on Vacuum booster parts

Operation for one-way valve inspection

(Gasoline engine)

(a)

Tear down the one-way valve;

(b)

Check the air to see whether it flows from the vacuum

booster side toward the engine side.

(c)

Check the air, change the one-way valve if the air flows

from the side of engine toward the vacuum booster.

(d)

Mount the one-way valve in the right place.

(a)

Tear down the one-way valve from the vacuum pipe.

(b)

Check the air to see whether it flows from the side of

vacuum room to the hose.

(c)

Check the air, and change the one-way valve if the air

flows to the hose to the vacuum room.

air

engine side

booster side

air

airless

air

hose side

vacuum side

air

airless

Mount of Vacuum Booster

1.

Adjust the length of vacuum booster pushrod:

(a)

Mount the sealing washer on the master cylinder;

(b)

Put SST on the sealing washer and descend the pin rod

until it contact lightly the piston with its top;

(c)

Put top of SST  downward ,and mount it on the vacuum

booster.

(d)

Check the clearance between the vacuum booster pushrod

and the head of pin on SST.

(e)

Adjust the length of vacuum booster pushrod until the

pushrod touches the pinhead.

2.

Mount the vacuum booster, sealing washer and Ushaped

clip head.

(a)

Mount the vacuum booster and sealing washer.

(b)

Mount the U-shaped clip head.

(c)

Mount and tighten the assembling nuts of vacuum booster.

3.

Connect the U-shaped clip head and the brake pedal:

Encase the U-shaped clamping pin in the hole of U-shaped clip

head and the brake pedal, and then mount the spring pin on the

U-shaped clamping pin.

SST

washer

SST

(Diesel engine)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-12

Brake System

Vacuum Booster

4.

Mount the pedal return spring.

5.

Mount the brake master cylinder

(see Page BR-8)

6.

Connect the hose and the vacuum booster.

7.

Fill the oil cup with brake liquid and exhaust the air in

braking system.

(see page BR-6)

8.

Check the liquid leakage;

9.

Check and adjust the brake pedal

(See page BR-5)

10. Check the operation

(See Page BR-6)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-13

Front Brake

Element figure

No. 2 lock plate of brake pad

No. 1 lock plate of brake pad

silent pad cluster

brake pad assembly

silent pad cluster

caliper body

No. 2 lock plate of

brake pad

No. 1 lock plate of

brake pad

long sliding caliper liner

sliding sleeve dust cover

caliper body

rectangular sealing ring

piston

piston dust cover

piston dust cover

snapping spring

sliding sleeve dust cover

short sliding caliper liner

short sliding caliper sleeve

sliding sleeve dust cover

vent screw

vent screw dust cover

long sliding caliper sleeve

sliding sleeve dust cover

Dr

Braking System

Front Brake (Dr)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-14

Brake pad change

Remark: Check the thickness of the friction material of brake

pad through the observation hole on caliper body after the

vehicle covers thirty thousand; if the thickness fails to fall

within the specified range, change is required. (If the brake is

used often, the thickness of friction materials of brake

pad is required to check whether it is within the specified

range after the vehicle covers more than ten thousand,

if not, change it.

1.

Tear down the front wheel;

2.

Check the thickness of friction material of brake pad:

Check the thickness of friction material of brake pad through

the observation hole on caliper body, if it fails to be within the

specified range, change it.

Min thickness: 2.0mm

3.

Raise the wheel-brake cylinder:

(a)

Tear down the short bolts of sliding sleeve;

(b)

Uplift the wheel brake pump and hang it with rope to

protect the brake oil pipe.

Remark: Do not loosen the brake oil pipe and the bleeding plug.

4.

Tear down the following parts:

(a)

Two braking pads;

(b)

Two silent pad clusters;

(c)

Four braking pad lock plates.

Braking System

Front Brake (Dr)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-15

5.

Brake disc measurement

(See page BR-17)

6.

Measure the radial run-out of the brake disc;

(See BR-18)

7.

Mount the lock plate of brake pad.

8.

Mount the new brake pad.

(a)

Mount the silent pad cluster on brake pads of both the

inner and outer sides;

Remark: Pollution of oil stain or coat is not allowed on the

work faces of brake pad or brake disc.

(b)

Draw out a little brake liquid from the liquid container to

prevent the brake liquid overflowing from the liquid

container;

(c)

Press in the piston with the hammer lever or similar tool.

9.

Mount the wheel-brake cylinder;

Mount and screw up the hex bolts (the hex bolts shall be coated

with the thread locking sealing agents.

Fastening torque

(38-50)Nm

Remark: only one brake pad can be changed in one time so as

to prevent the piston of other wheel being shot out.

Braking System

Front Brake (Dr)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-16

10. Mount the front wheel;

Screw up the fixing nut of wheel.

Fastening torque

(135150)Nm

Disassembly of Wheel-brake Cylinder

1.

Take apart the brake pipeline.

(a)

Tear down the brake pipeline. And block the outlet with

a clean cork.

(b)

Tear down the brake oil pipe bracket from the wheel-

brake cylinder.

2.

Tear down the wheel-brake cylinder from the caliper

bracket.

Tear down the two hex bolts and the wheel-brake cylinder.

3.

Tear down the brake pad:

(a)

Two brake pad;

(b)

Two silent pad cluster;

(c)

Four brake pad lock plate.

Pump Disassembly of Wheel brake

1.

Take apart the following parts:

(a) Two sliding sleeve;

(b) Four sliding sleeve dust cover;

(c) Two sliding liner.

Braking System

Front Brake (Dr)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-17

2.

Tear down the piston dust cover snapping ring and the

piston dust cover;

Tear down the piston dust cover snapping ring and the piston

dust cover with screwdriver.

3.

Tear down the piston from the wheel-brake cylinder:

(a)

Put a wooden plate between the piston and the caliper

body.

(b)

Tear down the piston from wheel-brake cylinder with the

compressed air.

Warning: Do not put your finger in front of the piston when

using the compressed air.

4.

Tear down the piston sealing ring from the caliper body.

Tear down the piston sealing ring with bent needle.

Notice: the tools used shall not be sharp so as not to

scrape the piston sealing ring.

Check the front brake parts

1.

Measure the thickness of brake pad liner;

Standard thickness

10.0mm

Min thickness

2.0mm

If the thickness is less than the min thickness or is unevenly

worn; change the brake pad.

2.

Measure thickness of brake disc

Standard thickness

25.0mm

Min thickness

23.0mm

If the brake disc is scraped, repair it, if the brake is serious

worn to the degree that its thickness is less than the min thickness,

brake disc requires to be changed

Braking System

Front Brake (Dr)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BR-18

3.

Measure the bouncing value of the brake disc face;

Remark: verify the bearing is aligned correctly before

measuring.

The bouncing value of max face: 0.11mm

4.

Change the brake disc according to the requirements

(a)

Tear down the calipers body from the steering knuckle.

(b)

Tear down the hub and the brake disc (See Page SA-11).

(c)

Mount the new brake disc and screw up the connecting

bolts according to the specified torque.

Fastening torque

(6079)N.m

(d)

Mount the hub and brake disc assembly (see page SA-12);

(e)

Mount the caliper bracket on the steering knuckle and

screw up the bolts according to the specified torque.

Fastening torque

(85105)N.m

Cylinder Assembly of Wheel-brake

1.

Preparation

All parts shall be washed, dried and cleared away the alien

materials before the assembly. And coat moderate vacuum

silicon base grease on the work faces of sliding sleeve dust

cover, sliding sleeve and the sliding liner; and plaster the

moderate rubber lubricant on the work faces of piston, piston

dust cover and the rectangular sealing ring.

2.

Encase the piston sealing ring and piston in the caliper body;

(a)

Screw the vent screw in the vent hole of calipers.

Fastening torque

(813)N.m

(b)

Coat moderate rubber lubricant on the work face rectan-

gular sealing ring and encase the caliper body in groove.

(c)

Encase the piston in the caliper body.

3.

Encase the piston dust cover and the dust cover

snapping ring in the wheel-brake cylinder.

Braking System

Front Brake (Dr)

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