Haima 7 User manual

Brand: Haima

Model: 7

Type: User manual

Brake system

Brake system ................................................................................................................................................... P-1

General steps .................................................................................................................................................... P-2

Conventional brake system .............................................................................................................................. P-2

Air exhaust ............................................................................................................................................... P-2

Inspection and adjustment of brake pedal ................................................................................................ P-3

Removal/disassembly/installation of brake pedal .................................................................................... P-4

Service of brake switch ............................................................................................................................ P-5

Disassembly/installation of brake master cylinder ................................................................................... P-5

Service of liquid level sensor ................................................................................................................... P-6

Disassembly/assembly of brake master cylinder ...................................................................................... P-6

Check of vacuum booster ......................................................................................................................... P-7

Removal/installation of vacuum booster .................................................................................................. P-9

Check of front disc brakes .............................................................................................................................. P-10

Introduction to the repair tips of brake judder ........................................................................................ P-10

Removal and installation of front disc brakes ........................................................................................ P-11

Removal and installation of the rear disc brake ..................................................................................... P-14

Parking Brake System .................................................................................................................................... P-17

Removal and Installation of Parking Brake Handle ............................................................................... P-17

Removal and installation of rear parking brake ..................................................................................... P-18

Check the parking brake handle ............................................................................................................. P-20

Adjustment of parking brake handle ...................................................................................................... P-20

Anti-lock brake system (ABS control unit) .................................................................................................... P-21

Check of ABS control unit and control unit ........................................................................................... P-21

Steps prior to determine the replacement of the ABS control unit ......................................................... P-23

Exhaust braking ...................................................................................................................................... P-26

Removal and installation of HU/CM of ABS control unit ..................................................................... P-29

Removal and installation of HU/CM of ABS control unit ..................................................................... P-30

Brake line connection diagram of ABS control unit 8 ........................................................................... P-31

Diagram of hydraulic pressure regulator of ABS control unit with ECU............................................... P-32

Definition of hydraulic pressure regulator pins of ABS control unit with ECU .................................... P-32

Removal and installation of wheel speed sensor on the rear ABS control unit ...................................... P-34

Check of Front/rear ABS control unit wheel speed sensor .................................................................... P-35

OBD ....................................................................................................................................................... P-36

ECU faults ...................................................................................................................................................... P-44

Brake system

P-2

General steps

Removal and installation of wheels and tires

1. This chapter does not include the removal and installation steps of wheels and tires. If necessary to

remove the wheel, they shall be retightened up at the installation time, to the specified torque in

88-127N.m {9.0-13.0kgf.m,65-94ft.lbf}.

Disconnection and connection of brake line

Attention

The brake fluid will damage the paint surface, thus, if the brake fluid stained the paint surface, please wipe it

up immediately

1. Use the SST(49 0259 770B ) to screw up the flare nut of brake line, the tightening torque of flare nut on

the brake line has to be adjusted to match with the use of combination tool——joint torque wrench

-SST(See——Moment Equation G1).

2. If the brake line used to be disconnected during the operation, the brake fluid shall be added, air in the

brake system exhausted, then check for any system leakage after the completion of work.

Disconnection of plug

Attention

1. Prior to the connector operation, the negative connection of battery shall be disconnected, the negative

connection can be remade up only after the completion of work.

Precautions to the operation of ABS control unit component

1. After the work of ABS control unit component completed, no fault codes shall exist in the ABS control

unit system. If there are fault codes in the diagnostic system, eliminate them(See——Fault Diagnostic

Function, ABS Control Unit System, steps to clean up the fault codes).

Conventional brake system

Air exhaust

Attention:

Whenever, the brake system shall exhaust, when

the brake line disconnected. If the hydraulic

piping is disconnected at the brake master

cylinder, the braking shall exhaust by starting

from the farthest slave cylinder, and then further

wheel cylinder until the exhaust of four

sub-cylinders completed. If the point of

disconnection is not located at the brake master

cylinder, then the exhaust shall start from the

nearest disconnection point from the brake slave

cylinders, and then the further wheel cylinder

until the exhaust braking 4 of cylinders completed.

Standard of brake fluid:

FMVSS DOT-3

1. Shore up with a jack a vehicle on a level ground

and hold the vehicle on a safe platform.

2. Remove the exhaust valve cap from the calipers

and fit up a vinyl pipe, transparent and not

corroded by brake fluid on the exhaust bolt.

3. Place another end of plastic pipe in a clean fluid

container.

4. The operator A steps down the brake pedal

several times, and then hold it on the depressed

position. The operator B unscrews the exhaust

bolt, drains the liquid, the operator A may release

the brake pedal, after the bleed bolt has been

retightened by the operator B with SST.

5. Repeat the steps 4 and 5 until bubbles appear

again.

6. During the air exhaust process, the fluid reservoir

shall be held at the 3/4 liquid level to prevent air

reentry again into the pipe.

Tightening torque: 5.9-8.8N·m (60-90kgf·cm)

Brake system

P-3

7. Check whether the brake is in normal operation.

8. Verify whether there is any spilled fluid, if yes,

wipe it off.

9. When exhausting of the brake is finished, fill the

brake with the brake fluid to the highest liquid

level.

Inspection and adjustment of brake pedal

Check of brake pedal height

Confirm that the distance between the central surface

of pedal pad and the carpet is within the designated

range

Pedal height (reference value): 250mm

Adjustment of brake pedal height

1. Disconnect the joint of brake switch.

2. Unscrew the lock nut A and turn the brake light

switch B until the thread section on the switch

just gets in contact with the pedal limit block.

3. Screw up the lock nut A so that the clearance

between the thread section of switch B and pedal

limit block is within the scope of the technique

requirements.

Technique requirements: 0.1-1.0mm

{0.004-0.039 in}

Tightening torque 14-17 N⋅m {140-180

kgf⋅cm, 122-156 in.lbf}

5. Connect the joint of brake switch.

6. After the adjustment, check whether the pedal

free travel and brake light are in normal

operation.

Check of free travel of brake pedal

1. Step down the pedal several times to clean up

the vacuum from the system.

2. Press down, with hand, the pedal to check the

free travel (until the resistance is felt).

Pedal free travel 6-10mm.

Height of brake pedal

Brake system

P-4

Check of the clearance between the pedal

and floor

1. Start the engine and then confirm that the

distance between the floor to the center of pedal

pad remains within the specified range, when the

pedal is depressed with the force in 147N

{15kgf}.

Specified vale: 130mm (min)

2. If the distance from the floor to the center of

pedal pad is less than the specified value, check

whether there is air in the Brake system.

Removal/disassembly/installation of brake pedal

1. Dismantle in the order of 6-7-8-9-10-11-2-3-5-1.

2. Install in the reversing order of removal.

1. Dismantle in the order of

4-12-13-15-14-16-17-19-18

2. Install in the reversing order of removal.

1 Brake switch plug 6 Flange nut

2 Stop pin 7 Flange nut

3 Spacer 8 Flange nut

4 Bushing 9 Flange nut

5 Vacuum booster push

rod

Flange nut

11 Locking bolt 16

Pedal swing arm

M10 Hexagonal nut 17

Limit block

Bolt pin 18

Brake light switch

Return spring 19

Lock nut M8

Spring sleeve

Clearance between the

brake pedal and the floor

Brake system

P-5

Service of brake switch

1. Disconnect the connection of brake switch plug.

2. Connect an ohmmeter between two terminals of

brake switch plug to check whether the circuit is

put through.

3. If inconsistent to the case as specified in the

table, replace the brake switch.

Disassembly/installation of brake master

cylinder

1. Remove in the order of 1-2-3-4-5-6-7-8.

2. Install in the reversing order of removal.

Liquid level sensor plug

Pipe clamp

Inlet hose of clutch master cylinder

Front cavity pipe of brake master cylinder

Rear cavity pipe of brake master cylinder

Flange nut

Brake master cylinder

Circuit put through

Terminal

Conditions

When the brake is stepped down

When the brake is not stepped down

Brake system

P-6

Service of liquid level sensor

1. Pull out the sensor plug;

2. Connect an ohmmeter on the plug;

3. Start measuring when the liquid level is more

than the max. value, and confirm the circuit is

not through at this moment.

4. Drain out the brake liquid and confirm that the

circuit is through when the liquid level is below

the min. value.

5. If inconsistent to the case as specified in the

table, replace the sensor.

Disassembly/assembly of brake master cylinder

Caution:

If the brake master cylinder body is damaged, the master cylinder shall be replaced. When the master

cylinder is fixed on a bench vice, only the flange disc of master cylinder is to be fixed.

1. Disassembly as per the order shown in the Table.

2. Assembly in the reversing order of disassembly.

1 Cover component

2 Screw

3 Fluid tank

4 Bushing

5 Bushing

6 Liquid level sensor

7 Retaining ring

8 Butterfly film

9 Piston sleeve

10 Retaining ring

11 1

stop pin

12 1

piston

13 2

stop pin

14 2

piston

15 Return spring

16 Master cylinder gasket

Circuit put through

Terminal

Conditions

Below the Min value

Above the Max value

Brake system

P-7

Installation instructions of stop pin

1. Aim the piston bore at the stop pin and fit on the

2nd piston and return spring.

2. Fit on the stop pin.

3. Push in and release the piston to confirm that the

piston can be locked by the stop pin.

Check of vacuum booster

Check the function of vacuum booster (simple method)

Attention:

Replace the vacuum booster when necessary.

Method 1

1. Shut down the engine; step down the brake pedal several times.

2. Hold pressed the brake pedal and start the engine.

3. If the pedal displaces slight downward after the engine started, it means that the vacuum booster is in

normal operation.

Method 2

1. Start the engine.

2. After the engine run for 1 or 2mins., shut down the engine.

3. Step down the brake pedal by the normal force, and hold it for 3-5s, so to allow the pressure difference

between the front and rear cavities equal to zero.

4. If the 1

travel of stepped pedal is long, and the 2

becomes shorter, it means that the vacuum booster is

in normal operation.

5. Attention:

If any problems found, inspect whether the check valve and vacuum booster hose are damaged and their

installation, repair or replace when necessary, and then check again.

Method 3

1. Start the engine.

2. Step down the brake pedal by normal force.

3. Hold the brake pedal on the depressed position and shut down the engine.

4. Hold the brake pedal on the depressed position for about 30s.

5. If there is no change in the height of brake pedal, it means that the vacuum booster is in normal

operation.

Brake system

P-8

(Check with a measuring instrument)

1. As shown in Fig., connect respectively with the SST vacuum gauge and pedal pressure detector.

Attention: Exhaust the air in the SST at the instrument A with a special instrument and a pedal pressure

detector.

2. After the air exhausted from the SST, detect as per the following steps:

a) Check the vacuum leakage

Under no-load:

1. Start the engine.

2. When the vacuum gauge reading reached 66.7kPa{500mmHg}, shut down the engine.

3. Shut down the vacuum gauge for 15s. If the vacuum indicates 63.3-66.7kPa {475-500mmHg}, it means

that the vacuum booster is in normal operation.

Under loading conditions

1. Start the engine.

2. Step down the brake pedal with the force in 196N {20kgf}.

3. Hold depressed the brake pedal, and shut down the engine when the vacuum gauge reading reached

66.7kPa {500mmHg}.

4. Observe the vacuum gauge for 15s. If the vacuum degree indicates 63.3-66.7kPa {475-500mmHg}, it

means that the vacuum booster is in normal operation.

b) Check the hydraulic pressure

1. Shut down the engine (vacuum degree: 0kPa {0mmHg}. If the fluid pressure is now within the specified

range, it means that the vacuum booster is in normal operation.

Pedal pressure Fluid pressure

196N{20kgf} 790kPa{8kgf/ cm

}min

Vacuum gauge

Pedal dynamometer

Brake system

P-9

2. Start the engine and step down the brake pedal when the vacuum degree achieved 66.7kPa{500mmHg}.

If the fluid pressure is within the specified range, it means that the brake device is in normal operation.

Pedal pressure

Fluid pressure

MTX

196N

{20kgf}

7100kPa{72kgf/cm

}min

ATX

8820kPa{90kgf/cm

}min

Removal/installation of vacuum booster

1. Remove the brake master cylinder

(See——Conventional brake system,

Removal/installation of brake master cylinder).

2. Remove in the order as shown in the Table.

3. Assembly in the reversing order of disassembly.

1 Vacuum booster hose assembly

2 Spring pin

3 Axle pin

4 Nut

5 Vacuum booster pump

6 Check valve assembly

Check of front disc brakes

P-10

Check of front disc brakes

Introduction to the repair tips of brake judder

There are three features as shown below in the problems of brake judder:

(1) Vibration of steering wheel. The steering wheel vibrates in the direction of rotation and such feature is

the most notable when braked at the speed between 100～140 km/h {62～87 mph};

(2) Floor vibration. In braking, the bodywork vibrates forward and rearward, and the vibration intensity is

not subject of the speed effect;

(3) Vibration of brake pedal. When the brake applied, there is impulsive force trying to push back the brake

pad, and transferred on the brake pedal.

The followings are some key raisons possibly resulting in brake judder:

When the brake disc jittered too much, the swing thickness between the one side and another is uneven. If the

judder is over 0.05 mm {0.002 in} at 10 mm {0.39 in} away from the edge of brake disc, it means the uneven

wear on the disc occurred due to the contact of the unbalances of pad and disc, if it is less than 0.05 mm

{0.002 in}, it means that no uneven wear occurred.

Thermal deformation of disc The repeated violent brakes may enable the disc local temperature to increase up

to about 1000℃ {1832ºF}, resulting in the disc distortion.

The thickness and friction coefficient of disc will change due to corrosion. If the vehicle parked for longtime

in wet condition, the friction surface of disc will be corroded. When the corrosion thickness is uneven, it will

take the corrugated shape, resulting in the variation of friction coefficient and the reaction force.

Check and repair process

Check the lateral run-out

1. Screw up, in crosswise, the hub nut to assure that the disc and hub properly were installed or the washer

inserted between the hub bolt and hub nut with the spacer thickness in10mm {0.39 in} and the I/D more

than 12 mm {0.47 in}.

Note:

The part composed by SST 49 B017001 or 49 G019 003 may be use as the suitable washer.

Identify the complains of clients

Carry out the radial run-out check

Refer to Radial Run-Out Check

Less than

0.05mm

(0.002)

Less than 0.05mm

(0.002)

resence

onfirm whether there have

been any brake jitters

emove the disc plate,

reinstall at another phase and

make again the radial run-out

check.

heck the thickness variation

(see

below)

Verify the repair

se the mold on the vehicle to

process the disc plate

Tighten all rim nuts by the same

torque to fix the brake disc and

measure the radial run-out.

ess than 0.015mm (0.

0005in)

More than 0.015mm (0.0005in)

ore than

0.05mm

(0.002in)

se the mold on the vehicle.

[Less than 0.015mm (0.0005in)]

Work completed

Not presented

More than 0.05mm (0.002in)

Check of front disc brakes

P-11

2. After all hub nuts screwed up to the same torque, place the dial gauge on the friction surface of brake

disc, at ca.,10 mm{0.39 in} away from the edge of disc.

3. Turn once the brake disc and measure the lateral run-out.

Run-out limit: 0.05 mm {0.002 in}.

1. Clean up with brake cleaner the friction

surfaces of brake disc and brake pad.

2. Measure, with a micrometer calipers, the

thickness of each point as shown in the figure.

3. Subtract, with the measured maximum value the

minimum value. If the result is nonconforming

to the requirements, process the brake disc with

grinding tool.

Variation limit of thickness: 0.015 mm {0.0005

in}

Warning

Don’t surpass the requirements of minimal brake disc

thickness.

Check the variation of thickness

Check the thickness of brake disc

Attention

If the disc is removed from the vehicle for processing, it will result in excessive run-out, thus the disc shall be

processed when fitted up on the vehicle.

1. Measure the thickness of disc. Replace the disc when the disc thickness is not within the range of

technique requirements, then,

The minimal thickness limit of front brake disc: 24 mm {0.94 in}

The minimal thickness limit of rear brake disc: 10 mm {0.39 in}

Check the thickness of brake pad

1. Jack up the front part of vehicle and shore it up

with the safety bracket.

2. Remove the wheel.

3. Check the residual thickness of pad and replace

the pad by full set. As long as the thickness of

one lateral pad of R/L wheels is less than or

equal to the requirement of minimal thickness,

the pads at both sides should be replaced at the

same time.

Pad thickness required: minimum value: 2.0 mm

{0.08in}

Removal and installation of front disc brakes

1. Remove in the order as shown in the Table

2. Assemble in the reversing order of disassembly

3. After installation step down the brake pedal several times, turn manually the wheel to confirm that no

brake blocking exists.

Check of front disc brakes

P-12

1 Brake hose

7 Guide pin cover

2 Caliper bolt 8 Guide pin

3 Front caliper assembly 9 Guide pin bushing

4 Compressing spring 10 Front brake disc

5 Internal/external friction plate

See——P Essentials to Removal of

Brake Disc

See——P Essentials to the Installation of

Internal/External Friction Plates

See——P Essentials to Brake Disc

Installation

6 Support beam 11 Bleed screw and bleed screw cap

Essentials to removal of brake disc

1. Prior to the removal, make the mark on the hub

bolt and brake disc for the reference at the

installation time.

Essentials to the installation of brake disc

1. Clean up any rust or grime on the contact

surface of brake disc and hub.

2. Align with the mark made prior to the removal

and fit up the brake disc.

Essentials to the installation of internal

/external friction plate

1. Push down to the end the piston with SST

2. Install the brake pad

Replace the internal/external friction plate

1. Disassemble in the order as shown in the Table.

2. Assemble in the reversing order of disassembly

Mark

Wood plate

Check of front disc brakes

P-13

1 Guide pin cover

2 Guide pin

3 Compressing spring

4 Internal/external friction plate

5 Support beam

6 Brake caliper assembly

Disassembly and assembly of front brake

caliper

1. Disassemble as per the order shown in the

Table.

2. Assembly in the reversing order of disassembly

1 Piston dust cover

2 Piston

See——P Essentials to the

Disassembly of Piston

3 Piston gasket

See——P Essentials to the

Disassembly of Piston Gasket

4 Bleed screw cover

5 Bleed screw

6 Front caliper body

Essentials to the piston disassembly

Attention

Slowly blow the compressed air into the brake caliper

to prevent sudden run-out of piston.

1. Place the SST into the brake caliper and then

slowly blow the compressed air from the hole

into the brake caliper, enabling the piston to be

pushed out from the brake caliper.

Check of front disc brakes

P-14

Essentials to the Disassembly of Piston Seal

Ring:

1. Push out, with the SST, the piston seal ring from

brake calipers.

Removal and installation of the rear disc brake

1. Remove in the order as shown in the Table

2. Assemble in the reversing order of disassembly

3. After installation, step down the brake pedal several times, turn manually the wheel to confirm that no

brake blocking exists.

1 Hollow bolt

See——P Essentials to the Installation of

Internal/External Friction Plate

2 Rear brake hose 7 Rear brake disc

3 Guide pin cover

See——P Essentials to the Removal Brake

Disc

4 Guide pin

See——P Essentials to the Installation of

Brake Disc

5 Rear caliper assembly 8 Guide pin sleeve

6 Internal/external friction plate 9 Bleed screw and bleed screw cover

Check of front disc brakes

P-15

Brake disc removal essentials

Prior to the removal, mark on the hub bolt and brake

disc for reference at the installation time.

Essentials to the Installation of Brake Disc

1. Clean up any rust or grime on the contact

surface of brake disc and hub.

2. Align with the mark made prior to the removal

and fit up the brake disc.

Essentials to the Installation of

Internal/External Friction Plate

1. Push out, with the SST, the piston to the end.

2. Install the brake pad.

Replacement of the Internal and External

Friction Plate

1. Disassemble in the order as shown in the Table.

2. Assemble in the reversing order of disassembly

1 Guide pin cover

2 Guide pin

3 Internal/external friction plate

4 rear brake caliper

5 Guide pin sleeve

Mark

Wood plate

Check of front disc brakes

P-16

Disassembly/assembly of rear brake

calipers

1. Disassemble as per the order shown in the

Table.

2. Assembly in the reversing order of disassembly

1 Piston dust cover

2 Piston

See——P piston disassembly

essentials to the

3 Piston gasket:

See——P piston gasket disassembly

essentials to the

4 Bleed screw cover

5 Bleed screw

6 Rear caliper body

Piston disassembly essentials to the

Attention

Slowly blow the compressed air into brake caliper to

prevent sudden run-out of piston.

1. Place the SST into the brake caliper and then

slowly blow the compressed air from the hole

into the brake caliper, enabling the piston to be

pushed out from the brake caliper.

Essentials to the Disassembly of Piston

Gasket

1. Remove with the SST the piston gasket from

the brake calipers.

Parking Brake System

P-17

Parking Brake System

Removal and Installation of Parking Brake Handle

1. Disassemble in the order as shown in the Table.

2. Assemble in the reversing order of disassembly.

3. Adjust the travel of parking brake handle.

Auxiliary instrument panel: See——S

Auxiliary Instrument Panel

Support spring and clamping pin of

brake shoe

Mounting bolts of parking handle and

bracket

10 Upper/lower return springs

3 Parking brake handle 11 Parking adjustment mechanism

4 Mounting bolt of parking cable 12 Push plate and brake plate assembly

5 Guide pin cover 13 Brake shoe

6 Guide pin

Front draw wire and rear parking

inhaul cable assemblies(L/R)

7 Rear brake calipers

8 Rear brake disc 15 Parking handle holder

Parking Brake System

P-18

Removal and installation of rear parking brake

1. Disassemble in the order as shown in the Table.

2. Assemble in the reversing order of disassembly.

3. After installation, adjust the brake shoe clearance and carry out the following jobs.

(1) Step the brake pedal several times and then confirm that no brake blocking exists

(2) Check the clearance between the pedal and floor.

(3) Check the travel of parking brake handle.

1 Rear brake disc

6 Parking adjustment mechanism

2 Clamping pin 7 Parking brake shoe assembly

3 Brake shoe support spring 8 Rear parking cable

4 Upper return spring 9 Push plate and brake plate assembly

5 Lower return spring 10 Rear mudguard

Parking Brake System

P-19

Check the thickness of parking brake shoe

1. Remove the lower brake disc;

2. Check the thickness of residual friction plate;

● As long as the thickness of one of R/L friction

plates is less than or equal to the minimal

thickness, the brake shoes at both sides should

be replaced at the same time.

Friction plate thickness:

Minimum value: 1.0 mm {0.04 in}

Check the inner drum head of rear brake

disc

1. Measure the I/D of the drum head of rear brake

disc.

I/D maximum value: 188 mm {7.40 in}

2. Check whether there are any scratches,

unevenness or abnormal wear on the inner

drumhead of rear brake disc.

3. Repair or replace the rear brake disc if

necessary.

4. Pay attention to check whether the drumhead is

in good contact with the brake shoe when the

rear brake disc is repaired or replaced.

Essentials to the removal of rear brake disc

removal

1. Prior to the removal, mark on the hub bolt and

rear brake disc for reference at the installation

time.

Mark

Parking Brake System

P-20

Essentials to the installation of parking

brake shoe

Note: Toggle up to tighten the parking adjustment

mechanism.

1. Clean up any rust and grime on the contact

interface of drum brake.

2. Align with the mark made prior to the removal

and fit up the brake drum.

3. As steps stated below, adjust the clearance of

brake shoe.

(1) Clean up any rust and grime on the contact

interface of inner drum of rear brake disc.

(2) Align with the mark made prior to the removal

and fit up the rear brake disc.

(3) Poke, with a screwdriver, the parking adjustment

mechanism, through the parking adjusting hole

on the rear brake disc until the parking shoe disc

fully got in tight contacted the brake disc.

(4) Poke downward the parking adjustment

mechanism for 3～5 teeth by the same method,

to assure the free rotation of brake disc.

Check the parking brake handle

1. Pull the parking brake handle several times.

2. Pull, by the force in 98 N {10 kgf, 72.3 ft.Ibf}, the parking brake handle and check the travel of parking

brake for 3－7 teeth.

Adjustment of parking brake handle

1. Pull apart the jacket zipper of parking handle.

2. Turn the adjusting nut on the front parking cable.

3. After the adjustment, check the following points:

(1) Turn on the ignition switch, pull the parking brake handle for one tooth to confirm that the parking brake

light is lit.

(2) Confirm that no brake blocking exists on the rear brake.

Parking adjustment mechanism

Parking adjustment hole

Adjusting nut

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Haima 7 User manual

Haima 7 User manual

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