Great Wall V200. Instruction — part 11
thickness Component No. thickness Component No.
Adjustment of front and rear brake belt
1. Setting procedure of brake belt
The setting procedure of brake belt is shown as follows:
a. For the calculating method of front servo mechanism thrust lever refer to Figure 8.62, dimension; standard A.
.Allow the air pressure is in 650/700kPa in the operating area of front servo mechanism (external of B1), (refer to
Figure 8.63).
. The forward dimension of thrust lever minus 3mm.
Dimension requirement for selection of shim:
Caution:
The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2.
.
Release air.
b. Proper shim to end of thrust lever pole.
Check the shim for damage, worn or corrosion; replace it if necessary.
The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.62.
Install the shim by hand, and not the hammer or pressure.
Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly.
c. Recheck the stroke of thrust lever 3mm
0.25mm.
2. Setting procedure of rear brake belt
The setting procedure of rear brake belt is shown as follows:
a. The setting of distance A is form the back surface of servo piston to inner surface of transmission, use the vernier caliper. Refer
to Figure 8.64.
A allows the air pressure of 650/700kPa is in the front servo mechanism operating area (external of B2), (refer to Figure
8.63).
Deduct 3.75mm from the movement of piston and use the 2.5 mm shim to divide the rest distance.
Caution:
The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2.
. Release air.
b. Select the proper shim for end of thrust lever pole.
Check the shim for damage, worn or corrosion; replace it if necessary.
The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.64.
Install the shim by hand, and not the hammer or pressure.
Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly.
c. Recheck the stroke of piston for 3.75mm
0.625mm.
Table 8.2 Effective thickness of shim
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Figure 8.62 Setting of brake belt
Figure 8.63 External port position of B1 and B2
Figure 8.64 Setting of rear brake belt
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O il filling procedure
According to the procedure described in 7.2.
Specification and special tools
T ype and specification
hydraulic torque converter
maximum torque multiplier factor
179K
stalled speed (80 to 100 ℃ rpm)
(179K torque converter )
Specification
2.00: 1
2090
G ear ratio
First gear
Second gear
Third gear
Fourth gear
Reverse gear
2.393:1
1.450:1
1.000:1
0.677:1
2.093:1
Lubricant
type
dry system
alternative of maintenance
Castrol T Q95
9.0 L (approximation)
4.5L (approximation)
Axial movement of gear assembly
0.50-0.65 mm
Fixed pinion axle movement
0.10-0.50 mm
Table 9.1- Type specification
Pressing factor of clutch
0588-000001
C1
structure (friction disk )
steel
5
5 (2)
C2
structure (friction disk )
steel
5
4 (2)
C3
structure (friction disk )
steel
4
4 (2)
C4
structure (friction disk )
steel
3
4 (1)
Table 9.2 Shifting point of clutch assembly details
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Shifting point
Opening
degree of
throttle
position
Shifting
1/2 2/3 3/4 4L
Opening
degree of
throttle
position
shifting
1/2 2/3 3/4 4L
0%
10 20 34 63 0%
14
26 41
87
40%
26
47 82 95 40% 30 56 76
113
100%
(WOT)
53 93 126 150 100%
(WOT)
53
94 127
152
decreasing 55 89 137
152
decreasing
55 96 137
152
Table 9.3- Shifting point-km/h
Maximum speed of typical Gear-decreasing of vehicle
The Gear-decreasing will be disabled when beyond the following speed.
Gear-decreasing type
Speed point for disable of Gear-decreasing
Instruction 2-1
In 59 km/h
Instruction 3-2
89 km/h
Instruction 4-3
119 km/h
Instruction 4-2 (4-2 direct)
68 km/h
Instruction 4-2 (sequence of 4-3-2)
89 km/h
Figure 9.4 - Special tools for maximum disable speed of instruction Gear-decreasing
Special tools
tools Part
No.
Platform bracket of transmission
oil pump remover
Cross shaft disassembly /installation
(brake lever)
clutch spring compressing tools
clutch assembly clearance positioning tools
Shaft end floating connector
Shaft end floating measuring tools
cross shaft seal disassembly tools
cross shaft seal installation tools
Pump sealing installation tools
Sealing ring expander extender /compressor
Cross shaft lever disassembly /installation
(disable switch)
solenoid valve /electric heating regulator,
electric meter
solenoid valve, platform meter
Assembly ball spool
Sealing gasket disc
Figure 9.5 Special tools
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Annex
Description for oil inlet hole of main housing
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Chapter 6
Drive shaft
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Cautions
Do not clamp the drive shaft bushing too tightened by the bench
vice to avoid the deformation.
failure Possible
causes
Method
Noise
The spline of universal-joint fork is worn
The intermediate bearing is worn
The cross-axle bearing is worn or jammed
Replace the universal-joint
fork
Replace the intermediate
bearing
Replace the cross-axle bearing
vibration
Runout of drive shaft
Unbalance of drive shaft
The rear bearing bushing of transmission
extended housing is worn
The spline of universal-joint fork is jammed
Replace the drive shaft
Replace the drive shaft
Replace the bushing
Replace the universal-joint
fork
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Front axle propeller shaft (4WD) assembly
Rear axle propeller shaft (4WD) assembly
N
m: Specified torque
universal-joint fork
front section of
rear axle propeller
shaft
intermediate sup-
port assembly
universal-
joint fork
shim
nut
circlip
cross-axle assembly
rear section assembly of
rear axle propeller shaft
flange fork
circlip
cross-axle assembly
axle tube assembly
front axle drive shaft assembly
N
m: Specified torque
universal-joint fork
circlip
cross-axle
assembly
drive shaft axle
pipe assembly
N
m: Specified torque
flange fork
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transmission
drive shaft assembly
rear axle assembly
front axle drive shaft assembly
transmission
rear axle drive
shaft assembly
transfer case
rear axle assembly
Disassembly of drive shaft:
Remove the intermediate support bolt of drive shaft firstly (CC6460KY
is without intermediate support connecting bolt ), then remove the
connecting bolt between the drive shaft and rear axle , lastly, pull out
the drive shaft assembly from the transmission output spline shaft and
remove it in integral.
Installation of drive shaft:
1
. Firstly, check the drive shaft for damage, spline for corrosion
and connecting surface for deficiency of damage or sand hole by
itself.
2
Install the connecting spline bushing of drive shaft on the
transmission output spline shaft carefully; then install the drive
shaft intermediate support on the intermediate support bracket
of carriage.
3
. Use the special drive shaft bolt, nut and spring shim to connect
the drive shaft to the vehicle axle ring flange and tighten it. The
tightening torque is 78
5N
m
4
. Tighten the drive shaft intermediate support nut, the tightening
torque is 63
5N
m (the front and rear drive shaft in
CC6460KY model are the integral and has the installation
content)
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Chapter 7
Suspension and vehicle axle
Rear suspension . . . . . . …112
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Troubleshooting
Failure Cause
Repair
content
Floating/pulling
The tyre is worn or charged improperly.
The front wheel alignment is incorrect.
The wheel bearing is adjusted too tightened.
The front /rear suspension components is loose or
damaged
The steering linkage is loose or worn
The steering device is connected unsound or worn.
Charge the tyre to the proper pressure or
replace the tyre.
Check the condition of front wheel
alignment.
Adjust the wheel bearing
Tighten or replace the suspension
partTighten or replace the steering
linkage
Adjust or replace the steering device
Subsidence of vehicle body
Overload of vehicle
vibration damper is worn
spring is weak
Check the load weight
Replace the vibration damper
Replace the spring
Left-right swing/up-down
bounce
The tyre is charged improperly
The stabilizer bar is bend or damaged
The vibration damper is worn
Charge the tyre to the proper pressure
Replace the stabilizer bar
Replace the vibration damper
Front wheel vibration
The tyre is worn or is charged improperly
Unbalance of each wheel
The vibration damper is worn
The front wheel alignment is incorrect
The wheel bearing is worn or adjusted badly
The ball joint or bushing is worn
The steering system is loose or worn
The steering mechanism is adjusted badly or damaged
Replace the tyre or charge it to the proper
pressure.
Balance all wheels
Replace the vibration damper
Check the condition of front wheel
alignment
Replace or adjust the wheel bearing
Check the ball joint or bushing
Tighten or replace the steering linkage
Adjust or repair the steering device
Abnormal abrasion of tyre
The tyre is charged improperly
The vibration damper is worn
The front wheel alignment is badly
The suspension part is worn
Charge the tyre to the proper pressure
Replace the vibration damper
Check the condition of front wheel
alignment
Replace the suspension part
Oil leakage of differential
High oil level or incorrect oil grade
The oil seal is worn or damaged
The matching flange is loose or damaged
Drain the oil to the specified level or
replace the oil
Replace the oil seal
Tighten or replace the flange
The axle has the noise
The oil grade is low or incorrect
The clearance of the pinion, ring gear or side gear is
large.
The ring, pinion gear or side gear is worn or broken
The pinion gear bearing is worn
The bearing of rear axle half shaft is worn.
The differential bearing is loose or worn
Fill with the lubrication oil or replace the
oil according to the specification
Check the clearance
Check each gear
Replace the bearing
Replace the bearing
Tighten or replace the bearing
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Front wheel alignment
1. Process the following inspection and eliminate
all problems
a. Check the wear condition of tyre and proper inflation.
Tyre inflation pressure: 230kPa
b. Check the wheel bearing of front wheel for loose.
c. Check the front suspension for loose.
d. Check the steering drive device for loose.
e. Process the standard elastic test; check thefrontvibration damper
for normal operation.
3. Install the 4-Wheel alignment instrument
Processed according to the detailed description of equipment
manufacturer.
4. Adjust the wheel angle
Remove the cover of spacing bolt of steering knuckle; check the internal
wheel’s steering angle A.
Internal wheel’s steering angle:
32
Caution: The wheel should not touch the brake hose of car body
when the steering wheel is rotated to limit.
2. Adjust the height of car
A:Adjust the height of car to the standard value for theconvenience of
processing the front wheel alignmentinspection.
B: Front fixed bolt of lower suspension arm
The standard no-load height is: the center of front fixed boltof lower
suspension arm is 295
1mm away form theground.
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6. Adjust the wheel toe
Adjust the wheel toe according to the following method
a. Shake the car upwardly and downwardly to make the suspension
reach the stable status.
b. Push the car forwardly for 5m in flat ground when the front
wheel is in the straight forward position.
c. Mark the center of each rear wheel; measure the distance “B”
between the marks of left and right tyre.
d. Push the car forwardly to move the mark on the back of tyre to
the position of front instrument.
Remarks: if the tyre moves too far, repeat the procedure (b).
e. Measure the distance “A” ‘between the marks on front of tyre.
f. Measure the toe of wheel.
toe =B-A
Inspection standard: 0-2mm
If the toe does not consist with the specified value, it can be
adjusted by the left and right draw-bar.
Move the vehicle forwardly
g. Adjustment of toe: the standard value is 0
2mm. The toe is
adjusted by rotating the cross draw-bar. When adjust the toe, it
should rotate the cross draw-bar on left and right side uniformly.
After the adjustment, tighten the lock nut, the tightening torque
is 55
65N
m.
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h. Check the sideslip
Sideslip: Within
5m/km
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Front hub and steering knuckle (2WD)
stabilizer bar
connecting rod
of stabilizer bar
flat shim
disk shim
fill block
shim
fill block
disk shim
absorber
bearing
hub cap
brake cover
spring shim
split pin
lower suspension arm
split pin
upper suspension arm
spring shim
brake caliper assembly
steering knuckle
tight nut
lock washer
screw
oil seal
bearing
hub and brake disc
flat shim
N
m: specified torque
Used component which can not be used any more
precoated component
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