Great Wall Florid. Manual — part 25

GWFLORID Maintenance Manual

98

Brake Pedal

Components

Areas of Importance

1. During removal, all components should be gently handled to avoid knocking, especially the junction

surface. All components should be placed in order to avoid losing or taking the wrong parts.

2. Keep all parts clean and free of dust, scuffs, rust, corrosion, oil build-up, or any other contaminants.

3. All rubbing surfaces in a relative motion must be coated with lubricant.

4. During installation, strictly adhere to the standard torque for installing nuts.

5. While installing the return spring, be careful to avoid operator injury from it bouncing back.

Troubleshooting

Symptoms

Possible causes

Eliminating methods

Brake pedal cannot return

to the original position

Return spring is broken

Replace the spring

Return spring's fixed end comes off

Check, secure in place

Feels slippery when

stepping on the pedal

Pedal pad is worn out

Replace

Pedal pad comes off

Reinstall

Stepping on the pedal

produces abnormal noise

The plastic bushing is seriously worn out

Replace

Spring broken

Replace

Spring's fixed end comes off

Check, re-fix

Pedal pad

Cotter pin

Return spring

Pedal shaft

Brake pedal bracket

welding assembly

Brake pedal lever

welding assembly

Bushing

Nut

Limiting stopper

Center pin

99

Brake System

Disassembly of the brake pedal assembly

1. Remove the lock nut with an outer hexagonal wrench.

2. Remove the pedal shaft.

Caution: Please do not place the pedal shaft directly

on the ground, as to guarantee its cleanness.

3. Remove the brake pedal assembly.

Caution: Set it down gently to avoid damaging its

surface finish.

4. Remove the pedal pad, bushing, and limiting stopper

from the pedal lever assembly.

Caution: Ensure cleanliness of the entire set's surface.

Installation of the brake pedal assembly

1. Apply lubricant on the inside of the axle tube-brake

pedal and the outside of the bushing, then install the

bushing into the axle tube-brake pedal.

Lock nut

Pedal shaft

Pedal lever assembly

Pedal pad

Axle tube

Bushing

GWFLORID Maintenance Manual

100

2. Install the pedal pad and limiting stopper to the pedal

lever.

3. Apply lubricant on the inner bushing and the outer

pedal shaft. Install the pedal lever assembly, pedal

shaft, and brake pedal bracket welding assembly.

4. Put on a nut, and tighten the nut and spring washer

using a 30 N·m torque.

Brake pedal examination and adjustment

1. Check if the pedal height is correct.

Height between pedal and the lower cowl panel: 109 mm

Pedal push rod's working empty stroke: 2 mm

2. Adjust pedal height if necessary.

(a) Disconnect the brake lamp's switch wire connector,

loosen the lock nuts, rotate the brake switch and

unscrew it until no contact with the brake pedal's

limiting stopper.

(b) Loosen the control rod lock nut and use combination

pliers to rotate the control rod and adjust the brake

pedal height to its standard value. After arriving at the

standard value, tighten the lock nut, and make sure the

working empty stroke of the pedal push rod is 2 mm.

(c) Rotate the brake lamp's switch and push it in until it

barely contacts with the brake pedal limiting stopper,

continue rotating 1/2-1 circle, then tighten the lock nut.

(d) Connect the brake lamp's switch wire connector.

(e) When the brake pedal is loose, the brake lamp should

be off.

Pedal height

Pedal pad

Limiting stopper

101

Brake System

3. Inspect the pedal free play.

When the engine is off, step on the brake pedal two to three

times, after the brake booster's influence is removed, push

the brake pedal by hand until resistance is felt, then measure

its movement (free play). Should satisfy standard value

regulation.

Pedal free play: 6-9 mm

4. Adjust pedal free play if necessary.

(a) If the stroke value is incorrect, rotate the pedal push

rod to adjust the free play.

(b) Start the engine to confirm the pedal free play.

(c) After adjusting the pedal free play, check the pedal

height.

(d) The relative height gap between the brake pedal and

the clutch pedal is 0-8 mm.

(e) The relative height gap between the brake pedal and

the accelerator pedal is 45±5 mm.

5. When the clearance between the brake pedal shaft

and the bushing is too big, one should remove and re-

place the pedal.

6. As shown, check if the pedal's remaining distance is

correct.

Pedal free play

Pedal’s remaining distance