Great Wall V200. Instruction — part 18
2. Install the rear bearing of drive bevel gear and ad
justing washer
a. Select the proper adjusting washer according to “Meshing Condi
tion of Drive Bevel Gear and Driven Bevel Gear”.
b. Install the rear bearing and selected adjusting washer by press
machine.
3. Install the spacer.
a.Select the adjusting washer between the rear bearing and spacer
based on the experience.
b.Install the spacer.
4. Install the front bearing inner race, oil baffle disc
and oil seal of drive bevel gear
a. Place the front bearing inner race in the reducer housing; place the
oil baffle disc.
b. Coat the position of reducer housing oil seal and lip of oilseal
with grease uniformly; place the oil seal in position. Start the
press machine for installation.
5. Install the drive bevel gear, flange and dustproof
cover assembly
a. Install the flange and dustproof cover assembly in the reducer
housing, Press it to level by hand.
b. Insert the drive bevel gear installed with the spacer, rear bearing
and adjusting washer into the flange through the spline; screw on
the nut.
c. Use the nut to tighten the flange, plain washer and drive gear.
special tools
level
special tools
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6 Use the special tools to clamp the flange; use the
torque wrench to tighten the nut.
Tightening force: 140
160N
m
7. Measure the rotation pretightening force of bearing
For new bearing : 1.2
1.7N
m
For reused bearing : 0.4
0.6N
m
If does not meet the requirement, replace the adjusting washer
under the spacer until meet the requirement.
Tightening torque : 0-3.5N
m
a. Reduce the thickness of adjusting washer if the measured value
is less than standard value;
b. Increase the thickness of adjusting washer if the measured value
is more than standard value.
8. Install the driven bevel gear on the differential
housing.
a. Use the bolt and lock plate to connect the driven bevel gear to the
differential housing.
b. Screw on for three rounds at least by hand; then use the pneu
matic wrench to tighten it properly.
c. Use the torque wrench to tighten it.
Tightening force: 65-95N
m
Caution: Tighten the bolt in diagonal .
Use the hand hammer and flat head punch to lock the lock plate.
Special tools
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9. Install the differential side bearing by press.
Use the press machine and special tools to install the side bearing
on the differential housing by press.
10. Install the differential assembly
a.Remove the bearing gland. Do not mix the left up with right.
b.Install the differential assembly in the reducer housing.
11.Install the adjusting ring
Use the adjusting ring to press the bearing outer race in position;
tighten it properly. Adjust the clearance between the drive and
driven gear to the proper dimension.
12. Install the bearing gland
a. Align the assembly mark on the bearing cover with that on re
ducer housing; Press down the press cover by hand.
b. Install the lock washer with double ears and nut; tighten the
hexagon nut by pneumatic wrench properly.
13. Adjust the engagement clearance between the drive
and driven gear.
a. Use the torque wrench to tighten four bolts on bearing cover by
torque wrench.
Tightening force: 78-115N
m
special tools
special tools
assembly mark
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b. Adhere the measuring meter base on the end surface of reducer
housing; the measuring head contacts the tooth surface; rotate
the driven gear by hand and measure the engagement clearance be
tween the drive and driven gear.
c. If the engagement clearance does not meet the requirement, use
the special tools to adjust the left and right adjusting ring until it
meets the requirement.
d. Recheck the engagement clearance between the drive and driven
gear.
Engagement clearance: 0.13-0.18mm
14. Check the meshing mark of drive and driven bevel
gear.
a. Paint 3-4 teeth with the red lead in three different positions of
driven bevel gear.
b. Rotate the driven bevel gear in clockwise and anticlockwise by
hand.Check the engagement of gear.
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sound contact
toe contact
dedendum contact
arge end contact
small end contact
select the shim which can make the small drive gear
close to the driven bevel gear
select the shim which can make the small drive gear away from the driven bevel gear
Select the proper washer from the table for correction if the intertooth
contacting status is bad. The thickness tolerance of washer is
0.01mm.
15. Install the stop washer and stop plate
a. If the drive and driven gear engagement mark meets the requirement,
then use the hand hammer and punch to lock the stop washer.
b. Install the stop plate, spring shim and bolt; tighten the bolt.
Tightening force: 18-25N
m
c. Use the punch and hand hammer to knock the lower end of stop
plate in the adjusting ring hole.
Set NO. Thickness
Set NO. Thickness
16. Measure the total pre-applied load
Pre-applied load : 1.8-2.4N
m
If the pre-applied load is beyond the specified; it should replace the
shim between the spacer and rear bearing until meet the requirement.
a. It should replace the adjusting washer if the pre-applied load is
more than specified value.
b. If the pre-applied load is less than specified value, it can retighten
the nut slowly and the torque should be no more than 160N
m.
Caution: When tighten the nut, if is beyond the Max. torque, re-
place the adjusting washer and repeat the pre-applied load process.
Do not reduce the pre-applied load by the method of screw off the
drive gear nut to loose.
washer
rear bearing
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17. Check and adjust the run-out of flange.
a.Adhere the dial indicator base on the reducer housing; make the
probe of dial indicator contact with the end surface of flange;
rotate the flange and watch the rotation range of the dial.
Full run-out tolerance of end surface: 0.10mm
b.Adhere the dial indicator base on the reducer housing; make the
probe of the dial indicator contact with the inner diameter of
flange; rotate the flange by hand , and watch the rotation range of
the dial.Radial full run-out tolerance: 0.10mm
18. Rivet the nut of drive bevel gear
Installation of reducer and differential assembly
1.Install the new stiffening ring
2.Install the reducer and differential assembly
Install the reducer and differential assembly in the rear axle housing;
place the washer and nut. Tighten the nut to the specified torque.
Tightening force: 18-25N
m
3.Install the reducer and differential assembly flange
on the drive shaft flange and align the assembly
mark; use four bolts and nuts to connect them.
Tighten the bolt and nut to the specified torque.
Tightening force: 78
5N
m
4.Install the oil drain plug; fill the differential with the
gear oil
oil number : GL-5 hyperbolic gear oil
Viscosity: SAE80W/90
Amount: Filled with oil until the oil flow out from the oil filling
port.
Tighten the oil filling plug.
Tightening force: 140-150N
m
assembly mark
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Differential
Differential
1
Remove the reducer and differential assembly
(Refer to “Removal of reducer”)
2
Remove the differential from the reducer and dif
ferential assembly.
(Refer to “Disassembly of reducer”)
Replacement of differential components
1.Disassembly of differential
Use the hammer and punch to knock out the pin. Remove the
planetary gear shaft, two half axle gears, two planetary gears and
two lock washers, two thrust plates.
2. Assembly of differential
a.Install the half axle gear and thrust plate of axle shaft gear
(Unit: mm)
b.Install the planetary gear and planetary gear lock washer in the
differential by rolling. (Unit: mm)
differential housing
thrust plate
half axle
gear
straight pin
planetary gear
lock washer
half axle
gear
thrust plate
planetary gear
lock washer
planetary gear shaft
Set NO. 1 2
Thickness 1.2 1.5
Set NO.
Thickness
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c.Use the feeler to measure the clearance between the thrust plate
and differential housing; it can be replaced by the thrust plate with
different thickness if the clearance is beyond the specified range.
Standard clearance: 0.45-0.75mm
d.Install the straight pin
Use the hammer and punch to knock in the pin through the hole
on the differential housing and planetary gear shaft. Rivet the pin
with the differential housing.
Installation of differential
1 Install the differential assembly in the reducer hous
ing
(Refer to “Assembly of Reducer”)
2 Install the differential
(Refer to “Installation of Reducer and Differential Assembly”)
f
eeler
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Rear suspension
N
m: specified torque
bush clip
bush
rear stabilizer bar
rear connecting rod of stabilizer bar assembly
plain washer
short longitudinal
pull-rod fixed bolt
rubber pad
short longitudinal
pull-rod fixed bolt
long longitudinal
pull-rod assembly
long longitudinal
pull-rod fixed bolt
long longitudinal
pull-rodassembly
short longitudinal
pull-rod assembly
rear axle
assembly
coil spring
upper support pad
of coil spring
short longitudinal pull-rod assembly
long longitudinal
pull-rod assembly
rear vibration damper
cross pull-rod assembly
cross pull-rod
connecting bolt
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Removal of vibration damper
1. Use the lifter to raise the car firstly, then support
the rear axle by bracket.
2. Remove the upper and lower fixing nut which is used
to fix the vibration damper; compress the vibration
damper by hand.
Remove the upper end firstly, then the
lower end; take out the vibration damper .
Installation of vibration damper:
1. Lower tightening force of vibration damper:
1 7 0
5 N
m .
Upper tightening torque : Compress the rubber block to 2/3 of
total height.
Caution: If the fixing nut of vibration damper is the lock nut, it
should be replaced by the new lock nut after replace the vibra-
tion damper.
Removal of coil spring:
1
. Remove the vibration damper (As previous )
2. Use the special tools to clamp the coil spring.
3. Place the car in the bounce status, take out the
coilspring
4. Remove the special tools from the coil spring.
Installation of coil spring:
1. Firstly, use the special tools to clamp the coil spring
to certain height (height when car is in bounce
status).
2. Cautions for installation: Adjust the rubber gasket on
the spring to ensure the spring in flat status.
3. Remove the special tools.
special tools
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Removal of connecting rod of stabilizer bar:
1.Shown as figure, firstly screw off the nut in the con
necting place between the connecting rod of stabi
lizer bar and carriage. (Need the inner hexagon
spanner ).
2.Screw off the nut connected to stabilizer bar in same
method; screw off the connecting rod.
Installation of connecting rod of stabilizer bar:
Tighten it to the specified torque during installation:
6 3
5 N
m
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Brake-1
Chapter 8
Brake
Cautions. . . . . . . . . . . . . . . . . . . . . .. 2
Troubleshooting. . . . . . . . . . . . . . . . . . . 2
Check and adjustment. . . . . . . . . . . . . . . . ..5
Brake pedal. . . . . . . . . . . . . . . . . . . . ..7
Parking brake. . . . . . . . . . . . . . . . . . . ...8
Front brake. . . . . . . . . . . . . . . . . . . . ...9
Rear brake. . . . . . . . . . . . . . . . . . . . ...16
Rear parking brake. . . . . . . . . . . . . . . . . ..22
Sensor load proportional valve. . . . . . . . . . . . . .29
Antilock Braking System (ABS). . . . . . . . . . . . ..31
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Brake-2
Troubleshooting
Cautions
Failure cause
Inspection
content
Pedal is low or soft
brake pad is worn
brake block is worn
brake system is leaked
master pump has failure
Brake system has air
Brake pump has failure
Auto adjuster of rear brake has failure
Replace the brake shoe
Replace the brake block
Repair the leakage
Repair or replace the master pump
Drain the air from brake system
Replace the brake pump
Repair or replace the adjuster
Lag of brake
Parking brake is adjusted badly.
Pull wire of parking brake is locked
Assist push rod is adjust badly
Extension spring or return spring has fault
Pipeline is blocked
brake pad is broken or deformed
brake block is broken or deformed
Auto adjuster is damaged
Master pump has failure.
Adjust the parking brake
Repair if necessary
Adjust the push rod
Replace the extension spring
Repair if necessary
Replace the brake shoe
Replace the brake block
Replace the adjuster
Replace the master pump
Brake is stagnant
Improper inflation of tyre
There is grease spot or lubricant oil on the
brake shoe or brake block.
The brake shoe is deformed ; the brake pad
is worn or smoothed
The brake block is deformed, worn or
smoothed
The brake drum or brake disc is deformed
Extension spring or return spring has failure
Wheel pump has failure
Pump has failure
Brake block is blocked
Charge the tyre to the proper pressure.
Find out the cause. Replace the brake shoe or block.
Replace the brake shoe
Replace the brake block
Replace the brake drum or brake disc
Replace the spring
Repair the wheel pump
Replace
Replace the brake block
brake pedal is hard
There is the grease spot or lubrication oil on
the brake disc or brake block.
The brake shoe is deformed; the brake pad is
worn or smoothed
The brake block is deformed, worn or
smoothed
Brake pump has failure.
Brake assist has failure
Improper vacuum degree
The brake pipeline is blocked.
Find out the cause .
Replace the brake shoe or brake block
Replace the brake block
Replace
Replace the assist
Repair if necessary
Repair if necessary
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Brake-3
Troubleshooting (continued)
failure cause
Inspection
content
The brake generates the
crack clatter during
operation.
(drum brake)
The brake shoe is blocked in the rear apron flange
The rear apron flange is worn
The brake shoe pull-out piece spring is loose or lost
The fixed bolt of rear apron is loose (disc brake )
Brake block support plate is loose or lost
Installation bolt is loose
Filled with lubricated oil
Replace the lubricant flange
Replace
tighten
replace
tighten
It has the rustle or rattler
when use the brake
The brake shoe gasket or brake block is worn
The brake caliper and wheel or rotor are disturbed
mutually
The dustproof cover and rotor, rear apron and brake
drum are disturbed mutually
Failure of other brake system component
Tyre generates the abrasion with the tyre and chassis
Replace, if the scratch is heavy,
then fine machine the brake drum or
rotor again
Replace it according to requirement
Correct or replace
Repair or replace it according to
requirement
Check or maintain
It has the squeak, continuous
scream, rattler or vibration
noise when use the brake .
Caution: The abrasion
material in the brake will
generate the inherent noise
and heat during the
abrasion, then emit the
heat. So it is normal that
generate the squeak by
accident. The condition
will be serious in extreme
environment, such as cold,
hot, high humidity,
snowing, saliferous and
mud. The accident squeak
will not cause the fatal
failure of the brake, and
will not reduce the effective
performance of the brake.
The brake drum and brake shoe gasket, rotor and
brake block is worn or scratched.
The brake pad or block is dirty, with oil or smoothed.
The brake pedal or assistor push bar is adjusted
incorrectly
(disc brake )
The brake block silencing plate is lost or damaged.
The abrasion of the brake block makes the brake
block abrasion indication plate contacts the rotor
The brake caliper has burr or is corrosive
(drum brake)
The pull-out piece spring of brake shoe is soft,
damaged or improper. The pull-out piece spring pin
and spring of brake shoe is loose or damaged; and
rear apron flange has crack
Check, repair or replace
clean or replace
check, replace
check and adjust
replace
replace
clean or remove the flash
check, repair or replace
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Brake-4
failure cause Inspection
content
It has the continuous
scream and squeak
when does not use the
brake
The brake pedal or assist push bar is adjusted
incorrectly
The return of brake assist or master pump or wheel
pump is bad
(disc brake )
The piston is corrosive or blocked
The brake block in brake caliper is in improper
position
Shell abrasion of rotor and brake caliper
The brake block support plate in disc brake is
installed improperly
The brake block abrasion indication plate contacts
the rotor for the abrasion of brake block
(drum brake)
The press spring of brake shoe is soft, damaged or
improper.
The flange of rear back rear apron is cracked
The rear apron interfere with the brake drum
mutually after bent or warp
Improper machining of brake drum, cause the mutual
interference of rear apron and brake shoe
components of other brake system:
Brake system has loose or redundant components
The brake pad is smoothed for the rear brake drum is
adjusted too tight
The wheel bearing is worn damaged or under
lubricated
Check and adjust
Check, repair or replace
Check and fill with lubrication oil if
necessary.
Repair or replacement
Repair or replacement
Repair or replacement
Repair
Repair
Repair or replacement
Repair or replacement
Replace the brake drum
Check, maintain and replace if
necessary.
It still has the rattler,
click or cackle noise
when does not use the
brake.
The stone or foreign enters into the inside of wheel
protecting hood
The hub nut is loose
The brake pedal or assistor push bar is adjusted
improperly
The wheel bearing is worn, damaged or lubricated
insufficiently
(disc brake )
The muffler spring is soft or lost; the brake block
support plate or external end of brake block is coiled
silencing plate is unsound
The slide bush is worn
The installation bolt is loose
Piston returns unsoundly
(drum brake)
Have loose or redundant component
Remove the foreign materials such as
the stone
Tighten it to the specified torque, it
should be replaced if the bolt hole is
enlarged
Check and adjust
Check, lubricate or replace
Repair or replacement
Check and replace if necessary
Check and replace if necessary
Check and tighten if necessary
Check , repair or replace
Check, take out or repair
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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
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