Great Wall Deer (2006 year). Service Instruction - page 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
-------------------------------------------------------------------------------------------------------------------------------------------------------------
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;
-------------------------------------------------------------------------------------------------------------------------------------------------------------
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
-------------------------------------------------------------------------------------------------------------------------------------------------------------
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
-------------------------------------------------------------------------------------------------------------------------------------------------------------
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
-------------------------------------------------------------------------------------------------------------------------------------------------------------
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)
-------------------------------------------------------------------------------------------------------------------------------------------------------------