Great Wall Hover. Manual - part 71

Brake-5

Check and adjustment

Check and adjustment of brake pedal

1.  Check the correctness of height of pedal

Distance from pedal to lower front apron: 152mm, Operating stroke

of pedal push bar is 1mm.

a. Disconnect the brake lamp switch wire connector; loose the

tightened nut; rotate the brake switch to the position not contacted

to limit block of brake pedal

b.   Loose the lock nut of operating connecting rod; use the thinnose

      pliers to rotate the operating connecting rod to adjust the height

       of brake pedal to the standard value; lock the block nut tightenedly

      when reach the standard value.

c. Rotate the brake lamp switch to contact with the limit block of

brake pedal; then rotate 1/2

1 round continuously; tighten the

block nut;

d. Connect the wire connector of brake lamp switch;

e. The brake lamp should not be light when the brake pedal is

released.

3. Check the free stroke of pedal

Free stroke of pedal: 4

6mm

In the status of engine is stop, step on the brake pedal for 2

3 times

after eliminate effect of the brake assist, push down the brake pedal

by hand to just with the resistance, then measure its displacement

(free stroke). It should be in accordance with the standard value.

pedal push rod

parking lamp switch

free stroke of pedal

pedal push rod

Brake-6

4. Adjust the stroke of pedal if necessary

a. Rotate the pedal push bar to adjust the free stroke if the stroke

length is improper.

b. Start the engine to confirm the free stroke of pedal.

c. Check the height of pedal after adjusts the free stroke of pedal.

d. The height difference of brake pedal and clutch pedal to front

apron is 0

8mm.

e. The height difference of brake pedal and accelerator pedal to the

front apron is 45

5mm.

Vacuum assist

Remarks:

Use the vacuum assist tester to check the operation of vacuum

assist if possible.

1. Operation inspection

a. Step on the brake pedal for several times before start the engine

and check the reserved distance which should not be changed.

b. Step down the brake pedal and start the engine. If the pedal

moves downwardly a little, then it means the normal operation;

if the brake pedal moves upwardly, then it means the brake

assist is damaged.

2. Air tightness inspection

a. Start the engine and shut off it after 1

2 minutes. Step down the

brake pedal slowly for several times. If the pedal moves

downwardly all long at the first time, but moves upwardly little

by little after second or third times, then it means the vacuum

assist has the sound air tightness. If the pedal height is without

variety, then it means the brake assist is damaged.

b. Step down the brake pedal when the engine is operating; then shut

off the engine but step down the pedal, if the pedal keeps the

stroke without variety within 30s, then it means the vacuum

assist has the sound tightness; if the brake pedal moves upwardly,

then it means the brake pedal assist is damaged.

Brake-7

Air discharge of brake system

Remarks:

It should discharge the air if operate on the brake system or as-

sume the brake system pipeline has the air.

Caution:

Must not keep the brake fluid on the paint surface, wipe off it if

has.

1. Fill the liquid reservoir up with the brake fluid.

Check the liquid level in liquid reservoir after discharge the air of each

wheel pump. Filled with the brake fluid if necessary.

2. Connect the polyethylene resin pipe to the overflow hole plug of

wheel pump;insert the other end of pipe into the container with

half of brake fluid.

Remarks:

When discharge the air of wheel brake pump, it should begin

from the longest pipeline.

3. Air discharge of brake system pipe

a. Step down the brake pedal slowly for several times.

b. Let the assistant presses down the pedal, at the same time screw

off the overflow hole plug until the brake fluid flows out. Then

switch off the overflow hole plug.

c. Repeat the procedure until the liquid is without air bubble.

Tightening torque of overflow hole plug: 11N

m

4. Process the same procedure for each wheel pump.

hexagon flange nut

brake bracket

 welded assembly

support sleeve

return spring

bush

screw bar

pin shaft

pedal cover block

rocker arm

welded assembly

Brake pedal

Brake-8

Replacement of pin shaft

Remarks:

When the connecting fork pin shaft and pin hole is over worn, it

should replace the pin shaft bush.

Remarks:

When the clearance between the brake pedal shaft and bush is

large, it should remove the pedal and replace the bush.

push bar

lock nut

inner distance

fork pin shaft

Parking brake

parking crank assembly

switch assembly

rear parking brake pull wire (R)

rear parking brake pull wire  (L)

brake pull wire clip

1. Adjust the parking crank assembly in position, 6

8 teeth.

2. When the parking brake pull wire is tightened, the torque should

be no more than 400N

m.