Great Wall Hover. Service Manual - part 19

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.

Brake-9

Front brake

front brake oil pipe

cliper bracket

outer silencing plate combination

lower circlip of

 brake block

brake block assembly

lower circlip of brake block

wear limitation alarm plate of brake block

lnner silencing plate combination

Inner brake block

silencing plate

upper circlip of brake block (I)

upper circlip of brake block (II)

piston

dustproof cover

guide pin dustproof cover

guide pin rubber cover

cooper washer

tong

air-bleed
bolt cover

location pin

guide pin dustproof cover

square seal ring

N 

m:       Specified torque

Piston

Replacement of brake block

Remarks:

When brake during the travel process, if the front wheel has the

continuous screams noise, then it should check the wear limitation

alarm plate of brake block. If the alarm plate has the abrasion

mark with brake disc, then it should replace the brake block .

1. Remove the front wheel

2. Check the thickness of abrasion material of brake block.

Check the thickness of abrasion material of brake block by the watch

hole on the tong.

Replace it if is not within specified range.

Min. thickness :   2.0mm

Brake-10

3

Lift the main body of brake caliper.

a. Remove the hexagon flange bolt.

b. Lift the brake pump and hang it by rope to protect the brake oil

pipe.

Remarks: Do not screw off the brake oil pipe and bleed plug.

4. Remove the following components

a. Two pieces of brake block

b. One piece of silencing plate

c.   Two piece of silencing plate combination

d. One wear limitation alarm plate of brake block

e. Four brake block circlip plates

5. Measure the thickness of brake disc

(Refer to step 2 of “ Inspection of component of front brake” )

6. Measure the circular runout of brake disc.

(Refer to step 3  of “Inspection of component of front brake”)

7. Install the brake block circlip plate

Brake-11

8. Install the new brake block

a. Install a wear limitation alarm plate of brake block on the inner

brake block.

b. Install a silencing plate and a silencing plate combination on the

inner brake block.

c. Install a silencing plate combination on the on the outer brake

block.

d. Install two brake blocks; let the wear limitation alarm plate is in

the inside of brake caliper.

Caution: It is unallowable that the operating surface of brake

block and brake disc is polluted by the grease and paint.

e.

Suck a few of brake fluid form the liquid reservoir (prevent the

brake fluid from overflowing from liquid reservoir).

f.

Use the special tools to press the piston .

9. Install the brake pump

Install and tighten the hexagon flange bolt.

Tightening force:   25

35N

m

Remarks:  Only can replace the brake block on a wheel in one

time to avoid the piston on another wheel is pushed out.

10. Install the front wheel

 Tightening force of the wheel fixing nut is 120N

m

11. Check whether the brake fluid level is in the specified position.

Brake-12

Removal of brake pump

1. Remove the brake pipeline

Remove the brake pipeline. Use a container to contain the brake fluid.

2. Remove the brake pump from the clamp bracket

a. Remove the hexagon flange bolt, location pin and guide pin.

b. Remove the brake pump.

3. Remove the brake block

a. Two brake blocks

b. One silencing plate

c. Two silencing plate combinations

d. One wear limitation alarm plate of brake block

e. Four brake block circlips

Disassembly of brake pump

1. Remove the piston form the tong

a. Place the wood block between the tong bracket and tong body .

b. Use the air gun or air pipe to aim at the brake oil pipe hole; remove

the piston form the tong.

c. Use the clean rag or soft cloth to take out the piston.

Warning: It must not place the finger in front of the piston when

use the compressed air.

2. Remove the piston gasket from the tong body.

Use the paper clip to remove the piston gasket.

Caution: The used tools must not be sharp to prevent from scratching

the piston gasket.

Brake-13

Check the component of front brake

1. Measure the thickness of the brake block bush.

standard thickness:   9.0mm

minimum thickness:   2.0mm

It should replace the brake block if less than minimum thickness or

has uneven abrasion.

2. Measure the thickness of the brake disc.

standard thickness:   26.0mm

minimum thickness:   24.0mm

It should repair or replace the brake disc if the brake disc is damaged

or worn or its thickness is

less than minimum thickness.

3. Measure the circular runout of the brake disc.

Remarks: It should ensure that the bearing is adjusted correctly

before the measurement .  maximum circular runout :   0.11mm

4. Replace the brake disc if necessary.

a. Remove the tong bracket form the steering knuckle.

b. Remove the hub and brake disc.  (Refer to section “Front hub”)

c. Install the new brake disc; tighten the connecting bolt to the

specified torque.

Tightening force:   90

100N

m.

d. Install the hub and brake disassembly.  (Refer to section “Front

hub”)

e. Install the tong bracket on the steering knuckle; tighten the

connecting bolt to the specified torque.

Tightening torque 140

10N

m.

Brake-14

Assembly of brake pump

1. Preparation work

All components should be washed, dried by wind and without foreign

material before the assembly. During the assembly, cost the guide pin

and location pin with proper vacuum silicon based grease; coat the

working surface of piston and square gasket with proper rubber

lubricant.

2. Install the piston gasket in the tong body.

a. Screw the bleed screw into the bleed hole;

tightening torque 7

10N

m.

b. Install the square gasket in the sealing groove of two cylinders of

pump respectively after coat its working surface with proper

rubber lubricant.

3. Install the piston with dustproof cover in the tong

a. Cover the dustproof cover on the piston.

b. Lengthen the dustproof cover to expose the bottom of piston

from the dustproof cover clip ring; use the tool (for example:  steel

wire about 

2mm ) to assist insert the clip ring into the cylinder

hole clip ring groove.

Caution: The used tools must not be sharp to prevent the damage

of dustproof cover.

c. Press the piston to the bottom of cylinder hole by hand.

4. Pre Install the guide pin and location pin on the tong bracket.

a. Install the guide pin dustproof cover on the guide pin and location

pin respectively.

b. Screw the guide pin and location pin in the tong bracket

respectively.

Caution: Do not damage the guide pin dustproof cover.

Brake-15

Installation of brake caliper

1. Install the brake block

2. Install the brake pump

a. Install the brake pump.

b.   Install and tighten the hexagon flange bolt.

Tightening force:   25

35N

m

3. Connect the brake pipeline

Connect the brake oil pipe to the tong body.

Tightening force:   50

5N

m

4. Fill up the brake liquid reservoir with the brake fluid and dis

charge the air in brake system.

5. Check for the leakage of brake fluid.

Caution: Discharge the air after the completion of replacement.

Brake-16

Rear brake  (Disk-and-drum type)

tong bracket

pin rubber cover

 brake caliper locking bolt 100

silencing plate

combination

outside brake block

inside brake block

brake block wearing
indication plate

c y l i n d e r   h o l e
dustproof cover

wire clip

rectangle seal ring

piston

tong body (left)

copper washer

brake oil pipe fastening blot 55

 location pin 25

30

bleed screw

bleed screw dustproof cover

guide pin 25

30

rear brake oil pipeline

N  m:      specified torque

peephole

silencing

plate

Replacement of brake block

Remarks: if the rear wheel generates the cheep during the braking,

it should check the abrasion indication plate of brake block. If the

indication plate has the abrasion mark with brake disc, then it

should replace the brake block .

1. Remove the rear wheel

2. Check the thickness of brake block bush.

Measure the thickness of the brake block bush (abrasion material)

from the eyehole of tong. If the thickness is not within the specified

range, then it should replace the brake block.

minimum thickness:   2.0mm.

Brake-17

3. Uplift the brake pump

a. Remove the location pin.

b. Uplift the brake pump and hang it with a rope to protect the brake

oil pipe.

Remarks:   do not remove the brake oil pipe.

4. Remove the following components:

a.  Two brake blocks

b. Two silencing plates

c. Two silencing plate combinations

d. One brake block bush wearing indication plate

e. Two brake block circlips

5. Measuring the depth of brake discs

(refer to the step 2 of measuring the components of rear brake)

6. Measuring the brake disc circular runout

(Refer to step 3 of measuring the components of rear brake)

7. Install the brake block Circlip

Brake-18

8. Install new brake block

a. Install a brake block bush wearing indication plate on the internal

brake block.

b. Install one silencing plate and one silencing plate combination on

each brake block.

Remarks: Coat the two sides of silencing plate with disc brake

oil (which cannot be replaced with oil of other models).

c. Install two brake blocks, make the wearing indication plate in the

lower position (near the tank cylinder).

Remarks: The working surface of the brake block and brake

disc are not allowed to be contaminated by grease and paint.

9. Install the sub pump

a. Unscrew the release screw, absorb some of the brake fluid.

b. Press the plunger with hammer beam or similar tools, and unscrew

the release screw at the same time.

Tightening force:   8

13N

m

Remarks: Only the brake block of one wheel can be replaced for

once, lest the plunger on the opposite side be bounced.

c. Install and tighten the location pin.

Tightening force:   25

30N

m

10. Install the rear wheel

Tightening force:   120N

m

11. Fill up with the brake fluid and drain the air in the brake

system after the completion of replacement.

Brake-19

Removal of brake pump

1.Remove the brake pipeline

Remove the brake pipeline. Use a container to contain the brake fluid.

2. Remove the pump form the bracket

a. Remove the location pin and guide pin.

b. Remove the tong.

3. Remove the brake block

a. Two pieces of brake block

b. Two pieces of silencing plate

c. Two pieces of silencing plate combination

d. One piece of brake block bush abrasion indicating plate

e. Two brake block circlips

Disassembly of brake pump

1. Remove the piston form the tong

a. Insert the cleaning cloth or other soft cloth into the place between

piston and tong.

b. Use the compressed air to remove the piston and cylinder hole

dustproof cover from the tong.

Warning: it must not place the finger in front of the piston when

use the compressed air.

2. Remove the piston gasket form the tong

Use the screwer to remove the piston gasket.

Brake-20

Check the components of rear brake

1. Measure the thickness of the brake block bush.

Standard thickness:   8.0mm

Minimum thickness:   2.0mm

It should replace the brake block if less than minimum thickness or

has uneven abrasion.

2. Measure the thickness of brake disc.

standard thickness:   18.0mm

minimum thickness:   16.0mm

It should repair or replacement brake disc if it is scratched or worn or

its thickness is less than  minimum thickness.

3. Measure the circular runout of brake disc.

Remarks: It should ensure that the rear bearing is adjusted

correctly before the measurement.

Maximum circular runout :   0.11mm

4. Replace the brake disc if necessary.

a. Remove the bracket form the rear axle flange.

b. Remove the rear brake disc and install the new brake disc .

c. Install the bracket and tighten the fastening brake caliper bolt.

    Tightening force:   100

5N

m

Brake-21

Assembly of pump

1. During the assembly, coat the guide pin with the proper vacuum

sili con based grease; coat the operating surface of piston and

square gasket with proper rubber lubricant.

2. Install the piston gasket and piston in the tong

3. Install the cylinder hole dustproof cover and wire clip in the

tong.

4. Install the rubber pin cover on the tong bracket.

Installation of brake caliper

1. Install the brake block