Haima 7. Brake system. Service Manual

Parking Brake System

P-17

Parking Brake System

Removal and Installation of Parking Brake Handle

1. Disassemble in the order as shown in the Table.

2. Assemble in the reversing order of disassembly.

3. Adjust the travel of parking brake handle.

Auxiliary instrument panel: See——S
Auxiliary Instrument Panel

Support spring and clamping pin of
brake shoe

Mounting bolts of parking handle and
bracket

Upper/lower return springs

Parking brake handle

Parking adjustment mechanism

Mounting bolt of parking cable

Push plate and brake plate assembly

Guide pin cover

Brake shoe

Guide pin

Front draw wire and rear parking
inhaul cable assemblies(L/R)

Rear brake calipers

Rear brake disc

Parking handle holder

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Parking Brake System

P-18

Removal and installation of rear parking brake

1. Disassemble in the order as shown in the Table.

2. Assemble in the reversing order of disassembly.

3. After installation, adjust the brake shoe clearance and carry out the following jobs.

(1) Step the brake pedal several times and then confirm that no brake blocking exists

(2) Check the clearance between the pedal and floor.

(3) Check the travel of parking brake handle.

Rear brake disc

Parking adjustment mechanism

Clamping pin

Parking brake shoe assembly

Brake shoe support spring

Rear parking cable

Upper return spring

Push plate and brake plate assembly

Lower return spring

Rear mudguard

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Parking Brake System

P-19

Check the thickness of parking brake shoe

1. Remove the lower brake disc;

2. Check the thickness of residual friction plate;

● As long as the thickness of one of R/L friction

plates is less than or equal to the minimal
thickness, the brake shoes at both sides should
be replaced at the same time.

Friction plate thickness:

Minimum value: 1.0 mm {0.04 in}

Check the inner drum head of rear brake
disc

1. Measure the I/D of the drum head of rear brake

disc.

I/D maximum value: 188 mm {7.40 in}

2. Check whether there are any scratches,

unevenness or abnormal wear on the inner
drumhead of rear brake disc.

3. Repair or replace the rear brake disc if

necessary.

4. Pay attention to check whether the drumhead is

in good contact with the brake shoe when the
rear brake disc is repaired or replaced.

Essentials to the removal of rear brake disc
removal

Prior to the removal, mark on the hub bolt and
rear brake disc for reference at the installation
time.

Mark

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Parking Brake System

P-20

Essentials to the installation of parking
brake shoe

Note: Toggle up to tighten the parking adjustment
mechanism.

1. Clean up any rust and grime on the contact

interface of drum brake.

2. Align with the mark made prior to the removal

and fit up the brake drum.

3. As steps stated below, adjust the clearance of

brake shoe.

(1) Clean up any rust and grime on the contact

interface of inner drum of rear brake disc.

(2) Align with the mark made prior to the removal

and fit up the rear brake disc.

(3) Poke, with a screwdriver, the parking adjustment

mechanism, through the parking adjusting hole
on the rear brake disc until the parking shoe disc
fully got in tight contacted the brake disc.

(4) Poke

downward

the

parking

adjustment

mechanism for 3～5 teeth by the same method,
to assure the free rotation of brake disc.

Check the parking brake handle

1. Pull the parking brake handle several times.

2. Pull, by the force in 98 N {10 kgf, 72.3 ft.Ibf}, the parking brake handle and check the travel of parking

brake for 3－7 teeth.

Adjustment of parking brake handle

Pull apart the jacket zipper of parking handle.

Turn the adjusting nut on the front parking cable.

After the adjustment, check the following points:

(1) Turn on the ignition switch, pull the parking brake handle for one tooth to confirm that the parking brake

light is lit.

(2) Confirm that no brake blocking exists on the rear brake.

Parking adjustment mechanism

Parking adjustment hole

Adjusting nut

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Anti-lock brake system (ABS control unit)

P-21

Anti-lock brake system (ABS control unit)

Check of ABS control unit and control unit

Check of the system

Precautions to the maintenance diagnostics of ABS control unit

The  ABS  control  unit  concerns  the  safety  parts;  therefore,  the  following  diagnostic  precautions  have  to  be
taken when other than in compliance with the  general safe and preventive  measures while other maintenance
diagnostics are carried out.

(a) The ABS control unit system has to be maintained by the technicians having received the professional

training and mastered the maintenance skills, and only original parts are allowed to use for replacement.

(b) Prior to the diagnostics of ABS control unit system, the conventional brake system shall run in normal

operation.

(c) Before and during the drive, the ECU of ABS control unit continuously monitors whether all electric

elements relevant to the ABS control unit are in sound operation.

(d) When the ignition switch turned on, the ABS control unit and EBD LIGHT have to be lit up, and in few

seconds, the ABS control unit and EBD alarm light shall go off in case of no faults in the system.

Note: The EBD alarm light and parking light are for public use. When the parking handle is pulled
up and the brake fluid too little, the alarm light will lighten up.

(e) The following two cases indicate that there are faults detested in the system:

① After the ignition switch turned on, the warning light will be held lit up for longtime;

② Do not go off once lit up in the driving process.

At this time, the driver may also perform the brake and minimize as much as possible the application of
braking force to prevent the blockage of wheel. Hence, cares must be taken to drive after the warning
light lit and have the ABS system checked and repaired at a special service station to prevent occurrence
of more faults, resulting in traffic accident.

(f) The hydraulic pressure regulator of ABS control unit with ECU comprises the following parts:

① ECU of ABS control unit: motor relay with reflux pump and solenoid relay;

② Solenoid (8pcs): including 4 inlet valves and 4 outlet valves;

③ Reflux pump and accumulator;

④ Others: motor and bolts etc.

They can be replaced by complete  unit instead  of being  knocked  down  or partially  replaced/exchanged.
No individual spare-part will be supplied.  And  no warranty  will be  undertaken  for the ABS control  unit
knocked  down  and  equipped  with  the  hydraulic  pressure  controller.  No  responsibility  will  be  taken  for
adverse  outcomes  resulted  after  the  hydraulic  pressure  regulator  of  ABS  control  unit  disassembled  for
check or partially replaced /exchanged

(g) Connection of ECU of ABS control unit.

① The ignition switch has to be disconnected when the ECU connector of ABS control unit is unplugged;

② Assure that the ECU connector of ABS control unit is kept dried and clean and no existence of any

foreign matters exists;

③ ECU connector of ABS control unit has to be installed in place: the lower part levels with the pedestal;

④ ECU connector of ABS control unit has to be installed in place: the lateral part is perpendicular to the

pedestal.

(h) The hydraulic pressure regulator of ABS control unit with ECU must be well grounded.

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Anti-lock brake system (ABS control unit)

P-22

For the imperfect measure of harness grounding, the connector, where water and moisture ingress, under
the effect of siphon, through the pore passages in the harness, into the ECU of ABS control unit, will
cause the function ineffective.

Measures taken: Smear sealant on the bare end of harness and apply the heat-shrink tube envelope.

Recommend use for sealant: Raychem sealant.

(i) When connecting the brake line of ABS control unit brake line, the correct connection has to be assured.

The ECU of ABS control unit is neither unable to judge whether the brake line is properly connected, nor
to perform the fault protection. Wrong connection may result in serious accidents.

The marks on the hydraulic pressure controller of ABS control unit vary depending to different
production places:

MC1: in connection with the brake line 1 of brake master cylinder;

MC2: in connection with the brake line 2 of brake master cylinder;

FL: in connection with the brake line of cylinder on the left front brake wheel cylinders;

FR: in connection with the brake line of cylinder on the right front brake wheel cylinders;

RL: in connection with the brake line of cylinder on the left rear brake wheel cylinders;

RR: in connection with the brake line of cylinder on the right rear brake wheel cylinders;

(j) The correct connection of wheel speed sensor has to be guaranteed.

Check the ABS control unit prior to the diagnostics

1. Be sure that the recommended specifications of tire and wheel are installed on the vehicle. The coaxial

style pattern and depth must be consistent.

2. Check whether there are any leakages in the hydraulic pressure regulator, brake line and connector.

3. Check the ABS control unit fuse.

4. Be sure that the battery has been fully charged.

5. Check whether there is any uncleanness in the battery connection or any looseness of terminals. Be sure

of the good grounding.

6. The parts of ABS control unit are very sensible to the electromagnetic interference. If any intermittent

faults suspected, check whether the anti-theft device and on-board mobile phone added after sales are
correctly installed.

Tightening bolts (4pcs)

ABS control unit (with
reflux pump motor and

solenoid relay)

Solenoids (8pcs) [4

input valves and 4

output valves]

Hydraulic

controller

Reflux pump

motor

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Anti-lock brake system (ABS control unit)

P-23

Noise

1. Self-tested sound system

After the engine started, short noise “Buzz” will come out from the engine compartment when a running
vehicle reached at 15km/h. It is a normal phenomenon as noise produced by the self-test of ABS control
unit.

Sound when the ABS control unit plays role

a. Motor sound from the hydraulic pressure unit of ABS control unit

b. Noise produced by the vibration together with the brake pedal

c. During the operation of ABS control unit, impact noise of suspension produced by the braking

3. If the noise is too loud when the system makes the self-test or the ABS control unit plays role, it

may be caused by the following reasons:

a. The fixation of ABS control unit and holder is loosened;

b. The fixation of ABS control unit holder with the bodywork is loosened

c. The connection fixing the brake lines is loosened

d. There are bulbs in the brake line.

Steps prior to determine the replacement of the ABS control unit

Dynamically self-check:

1. After the troubleshooting, the speed shall not be lower than 15km/h to enable the ABS control unit for a

dynamically self-check.

2. As the ABS control unit fault light will keep will not go off, the re-ignition is necessary after the

troubleshooting  (e.g.  the  wheel  speed  sensor  signal  unstable  or  motor  fault).  Only  when  the  vehicle
reached to about 15km/h  and  after the ABS control  unit  passed through the  dynamically  self-check, the
ABS control unit fault light can go off.

Cross validation:

Remove the  ABS  control  unit and install on another trouble-free  vehicle  using an  ABS control  unit of same
model.  It  is  only  necessary  to  plug  in  the  connector  of  ABS  control  unit  sensor  harness  instead  of  oil  pipe.
Reignite  the vehicle and suspend it  on  a lifter and have it turn  on air.  Let the  ABS control  unit carry  out the
dynamically self-check with the speed not lower than 15km/h.

1. If the alarm light of ABS control unit is still lit, it indicates that faults really exist in the ABS control unit.

The ABS control unit can be replaced.

2. If the alarm light of ABS control unit is off, it indicates that there are no faults in the ABS control unit.

Please rearrange the investigation as per the service manual

When operating according to the above steps, be sure that the ABS control units on two vehicles are of
same model and the ABS control unit plug tightly plugged in, otherwise it will result in unstable circuit.
Poor contact will cause the signal of wheel speed sensor distorted.

Requirements relevant to the Haima vehicle analysis for the product reject

The product warranty period provided by the Haima vehicle to the customer is 2 years, i.e. 60,000kms.

For the products, which are returned for the Haima vehicle analysis, an visual check shall be made at

First with the items as below:

1. No visual damages on the product

2. The ABS control unit not yet disassembled

3. No scratches on the ECU pins of ABS control unit

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Anti-lock brake system (ABS control unit)

P-24

4. No rust and water stain on the ECU slot of ABS control unit

Relevant Information to be supplied by the customer for the failure analysis made on the Haima vehicle:

1. Information of dealer/maintenance and repair network

2. What diagnostics have been made by the fault information description as well as the maintenance and

repair network?

3. Mileage

4. Dates of fault and maintenance

5. When the fault came about, e.g.: speed, roadway and environment etc,.

6. VIN code

Preparations

1. Be sure that the vehicle is only fitted up with the tires and wheels of recommended size and the coaxial

style pattern same as the depth.

2. Check whether there are any leakage in the hydraulic pressure regulator, brake line and connector.

3. Check the fuses of ABS control unit——10A, 25A and 40A. Be sure to only use the fuse of correct size.

4. Confirm that the battery has been adequately charged;

5. Turn the ignition switch in the ON position. Confirm that the alarm light of ABS control unit goes off in

2—4s.  If  the  alarm  light  keeps  lit  in  2-4s,  it  means  that  the  control  modular  of  ABS  control  unit  has
detected  the  faults  and  won’t  trigger  the  hydraulic  pressure  unit  of  ABS  control  unit.  Carry  out  the
maintenance of Fault Diagnosis Process;

Turn the ignition switch to Off;

7. Jack up the vehicle on a level ground by use of a jack, shore up the vehicle on a safety seat, and shift the

gearbox on the N position.

8. Release the parking handle.

9. Turn manually the wheel to check whether there are any scratches on the brake.

Use of SST

(1). Complete the preparations

(2). Connect the NGS tester of SST to the joint of data connection;

Note: Perform by use of the manual in compliance with the SST NGS instruction.

(3). Set up the active control mode as per the following combination order. Check the (See——P ABS

control unit OBD)

Function

Name of order

Type of orders

PMP motor RF outlet RF inlet

RLY

Pressure maintenance

Off

Manual

Pressure reduction

Above is an example of right wheel inspection

Note: In case of the work performed by two persons, one should step on the brake pedal while the other tries
to turn the checked wheel.

(4). Step the brake pedal and give the order while trying to turn the checked wheel.

(5). While holding the pressure, the clicks out of the ABS control unit HU/CM indicate that the solenoid is in

normal operation. Confirm that the wheels are not rotatable. When reducing the pressure, the clicks out

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Anti-lock brake system (ABS control unit)

P-25

of ABS control unit HU/CM mean that the solenoid works properly. Confirm that the wheels can rotate
even if the brake pedal was depressed.

Non-use of SST

1. Completion of preparations

Attention：Wrong  connection  with  the  data  cable
may  result  in  faults.  Therefore， carefully  make
connection,  which  is  only  allowed  to  the  specified
terminal.

2. Connect by use of a jumper, the TBS terminal of data

transmission plug with the GND terminal;

3. Step down the brake pedal and have your assistant

confirm that the front wheel is unable to rotate.

4. Hold the brake pedal stepped and turn the ignition

switch in the ON position. Confirm that the brake will
be released in an instant (ca., 0.5S), and the wheels can
be rotated when the pressure is reduced.

Check, in sequence, the operations of other wheels:
right front; left front; right rear and left rear.

Note:

If the wheels do not rotate，replace the hydraulic
unit of BS control unit;

If the wheel runs, but in wrong sequence, check
the brake pipe in connection with the hydraulic
unit of ABS control unit.

Attention:

If the operation is proved normal by the steps 4
and 5, it indicates that the system is normal:

— In connection with the hydraulic unit brake oil of

ABS control unit

— Including the hydraulic unit brake system of ABS

control unit.

— Electric systems inside the ABS control unit

hydraulic unit (solenoid valve, ABS control unit
and motor etc.,)

— Control module of ABS control unit, output

system and harness of control module.

The above steps excluding the check of the following
items:

— The input system and harness of ABS control unit

control module.

— Intermittent fault.

— Liquid leakage.

Turn the ignition switch in the OFF position and
remove the jumper connecting the TBS and GND
terminals.

Jumper

Ignition switch

Pressure

Low

Normal

Motor

Right

front

Left

front

Right

rear

Left
rear

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Anti-lock brake system (ABS control unit)

P-26

Exhaust braking

1. The brake system can be exhausted artificially. The customer service may choose the following three

exhaust processes:

— To exhaust by a filling unit (2 bar exhaust)

— To exhaust by the artificial pedal

— To exhaust jointly by the artificial pedal and filling unit.

Statement:

● The exhaust braking can be executed during the processes of the first loop and the second loop.

● After the customer replaced the brake system elements (e.g. replace the brake fluid and braking system

elements, hydraulic pressure unit), or the brake pedal became softer, the exhaust has to be made.

● The hydraulic pressure unit replaced by the customer has to be wet typed ABS control unit with ECU.

●

During the exhaust process, it must be assured that the brake system is in complete structure and all HP
hydraulic pressure units are in sound connection.

● Prior to the exhaust, it is necessary to set the gear position in the N-position and pull up the parking

handle.

● As the brake fluid is somehow corrosive. If stained on your skin by imprudence, you have to clean it up.

To exhaust by use of an exhaust/filling unit (exhaust for 2 bars)

Connect the exhaust/filling unit to the liquid storage tank, confirm that there is

sufficient braking liquid to turn on the switch. Set up the pressure to 200bars

Open the release screw at the left wheel cylinder until the bubbles are exhausted.

Check the travel of pedal

If failed, repeat the exhaust of every wheel

Check the level of braking liquid and assure that it is kept between the max. and min.

levels.

Artificial pedal exhaust

Fill up the liquid storage tank(until reached over the filter neck)

Repeat the following procedure to exhaust the air in each wheel cylinder.

Sequence: left rear; left front; right front and right rear.

Open the exhaust screw

Repeatedly step down the brake pedal

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Anti-lock brake system (ABS control unit)

P-27

Close the exhaust screw

Release the brake pedal

Check the travel of pedal

If failed, repeat the air exhaust

Check the level of brake liquid, and assure that it is kept between the max. and min.

levels.

Exhaust by artificial pedal in combination with the exhaust by filling unit

Connect the exhaust/filling unit to the liquid storage tank, confirm that there is

sufficient braking liquid to turn on the switch. Set up the pressure to 200bars

Repeat the following procedure to exhaust the air in each wheel cylinder.

Sequence: left rear; left front; right front and right rear.

Repeatedly step the brake pedal

Check the travel of pedal

If failed, repeat the exhaust of every wheel

Check the level of brake liquid and assure that it is kept between the max. and min.

levels.

Remark:

● The recommended sequence for X –loop: left rear, left front, right front and right rear

● If decreasing the pressure before opening the screw. The correct grade of filling is normally set

automatically

● During the whole exhaust process, the brake fluid in the tank (container) cannot be lower than the lowest

scale.

5. Artificial exhaust diagram

Artificial exhaust diagram of X-loop of 4-way ABS control unit: left front wheel

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Anti-lock brake system (ABS control unit)

P-28

Function mode:

The brake fluid flows, through the master cylinder and hydraulic pressure unit, into wheel cylinder. Open the
bleed screw on the left front wheel, the bleed screws on other wheel are closed. Repeatedly step on the brake
pedal until the bubbles and impurities have been cleaned out and the brake fluid purified. Repeat the same
procedure on other three wheels.

X- braking look

Vacuum degree: 2bars

Braking look 1

Braking look 2

Backflow 2

Backflow 1

Left rear input

valve

Accumulator

Right front
input valve

Right rear

input valve

Left front

input valve

Right front

output valve

Left rear

output valve

Right rear

output valve

Left front

output valve

X- braking look

Vacuum degree: 2bars

Braking look 1

Braking look 2

Backflow 2

Backflow 1

Left rear input

valve

Accumulator

Right front
input valve

Right rear

input valve

Left front

input valve

Right front

output valve

Left rear

output valve

Right rear

output valve

Left front

output valve

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Anti-lock brake system (ABS control unit)

P-29

Removal and installation of HU/CM of ABS control unit

Caution

●

Do not let the ABS control unit drop down to the floor. If they are subject of an impact, then they shall be
replaced.

Attention

●

The pressure unit of ABS control unit hydraulic is purchased as an integrated part with the control
modular of ABS control unit. If any one of two functions lost efficacy, the pressure unit of fault ABS
hydraulic or fault ABS control modular shall be replaced entirely instead of separately.

Remove the air filter assembly, battery and intake hose.

Remove as per the order as shown in the Table.

Install in the reversing order of removal.

Harness connector

Nut

Driven cavity tubing of brake master
cylinder

Nut

Drive cavity tubing of brake master
cylinder

ABS control unit modular

Right front brake lines assembly

Locking bolt

Left front brake lines

Locking bolt

Front end of left right brake line

Locking bolt

Front end of right rear brake line

ABS control unit holder

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Anti-lock brake system (ABS control unit)

P-30

Removal of plug

l Confirm that the locking rod of plug is

completely tightened;

l Pull up completely the locking rod at the

removal time;

l Pull out the ABS electric connector.

Removal and installation of ABS control
unit holder

Removal and installation bolt.

Remove the ABS control unit holder.

Remove the ABS control unit.

The installation process is in the reversing order
of removal process.

Nut

Locking bolt

Nut

ABS control unit
holder

ABS control unit
modular

Buffer cushion

Locking bolt

Removal and installation of HU/CM of ABS control unit

Thrust bar

Direction where the

force is applied

Direction where the

force is applied

1. Initial state

2. Fit up the left buffer

element (facing the engine)

3. Insert the central pin

4. Install the nut

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Anti-lock brake system (ABS control unit)

P-31

Brake line connection diagram of ABS control unit 8

Vacuum booster

Braking liquid tank

Brake master pump

Braking pedal

Braking pipe of master pump 2

Braking pipe of master pump 1

ABS hydraulic regulator

Damper

Backflow pump 2

Backflow pump 1

Motor of backflow

pump

Check

valve

(4)

Accumulator

Brake slave

pump

Brake slave

pump

Brake slave

pump

Brake slave

pump

Left rear input

valve

Left front

input valve

Right front input valve

Right rear input valve

Left front output valve

Right rear output valve

Left rear output valve

Right front output valve

Right front

wheel

Left rear

wheel

Right rear

wheel

Left front

wheel

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Anti-lock brake system (ABS control unit)

P-32

ECU terminal definition

Diagram of hydraulic pressure regulator of ABS control unit with ECU

Check the HU/CM of ABS control unit

1. Disconnect the negative connection of battery.

2. Turn off the ignition switch and the tester

between the HU/CM of ABS control unit and
harness joints.

3. Connect the lead of tester to the special tool, and

check the terminal voltage according to the
following table.

Definition of hydraulic pressure regulator pins of ABS control unit with ECU

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Haima 7. Brake system. Service Manual - part 2