P201 Product Training

——Brake System

Formatted by ：
Verified by ：
Confirmed by ：
Parameters of Brake System

Assembly parts Parameters

Pedal Hanging type ， lever ratio ： 3.27 ， Pedal arm length ： 338

Master cylinder and Center valve type ， Cylinder diameter 25.4 ； 8+9 Double diaphragm ； Power
boost assembly ratio ： 7 ： 1 ； Jumping value ： (700~850)N
Double cylinder fixed caliper ， Cylinder diameter ： φ 45.3 ； effective radius ：
Front brake
133mm ； rated torque ： 2900N.m pads area ： 5060mm2
leading-trailing drum brake ， Cylinder diameter 26.99 ； drum diameter ：
Rear brake
295mm ； lining area ： 14666mm2 ； rated torque ： 1450N.m

parking brake cable Brake away force≥8500N ； load efficiency 、 Stroke efficiency≥85%

parking brake lever ratio of the ratchet type ； Active arm length ： 245mm ； implement total
hand lever parking In 8 ~ 10 tooth; lever ratio ： 4.5 ： 1
 statement of calculation about P201 brake system
1 、 Vehicle parameters Associated with the brake system ：

Parameters no-load full load

Distance between gravity center to

1285 1747
front axle a (mm)

Height of gravity center to hg

789.5 889.9
(mm)

Total mass Ga (kg) 1950 2900

Front axle load G1 (kg) 1143 1268

Front axle weight distribution % 0.59 0.44

Rear axle load G2 (kg) 807.0048 1632

Rear axle weight distribution % 0.41 0.56

 The structure and working principle

Major components including:

Master cylinder and boost assembly, ABS module, sensors and
wiring harness, brake lines
Explored view of ABS module
 Hydraulic Diagram

accumulator

Electrical
motor

Cut off valve

Release valve

brake cylinder

Cut off valve energized – block pressure fluid from master cylinder
Release valve energized – open passage from wheel cylinder to accumulator
 Tunland ABS control (diesel engine)

Ignition
Battery
key
Fuse box Fuse box Instrument gauge
under hood under dash
Brake
switch

ABS control unit

G-speed
sensor

Wheel speed sensors

1 、 Note about installment of Vacuum booster with reservoir assembly

Brake fluid cup ：

Special requirement ： brake fluid level filled in oil
storage cup min≤H≤max, make sure the level is as
closer as possible to max when first filling.

Vacuum booster:
Adjust push rod length, Make sure A=159mm while
installing, then adjust the pedal height accordingly.

Vacuum booster system:

Pipe installed securely, pipe and steel tube
connected reliable, no leakage in the system
 Vacuum line on boost
With clutch vacuum assist

Vacuum line on boost

Without clutch vacuum assist
 Brake lines and wiring harness

Primary

Secondary

Front sensor and wiring ABS module and connections

Rear brake line Sensor connector color coded

Rear sensor wiring
Red-left ; Blue-right
 Brake replacement
Specification:
Disc thickness new 22mm, limit 21mm Pads: new 7mm, limit 1mm
Drum diameter new 295 mm, limit 294mm Shoes thickness new 7mm, limit 2mm

No need to remove calipers to

replace brake pads
 Matters needing attention in the installment and inspection ：
1.Pedal installment and adjustment
Feature: brake stroke “E”
Pedal height “D”is the
vertical distance from Feature requirements: the brake pedal working stoke shall not exceed
center of pedal plane to
the floor
3quarters of its total stroke.

F view
Pedal height : 155~160mm(without carpet); 147~152 （ with carpet ）
clevis

Adjustment of pedal height “D”

1.First adjust the brake light switch to reach the required pedal height
i ew
Fv 2. adjust push rod clevis( showed in the picture), align clevis pin and
pedal arm hole, lock the jam nut.

There are 3 dabbers on the floor board under the

pedal.
Park brake cable mechanism over view
2.Installment and Adjustment of parking brake ：
Right cable adjusting
mechanism
Position of 3 to 4 teeth

Initial Position

1. Jack up rear axle. Loosen up main cable at handle fig.1

2. Set intermediate cam plate as shown in fig.2 to ensure 20 degrees.
3. Turn RH cable adjuster till no slack without moving the cam plate.
4. Re-tighten main cable at handle and set main cable adjusting nut.
5. Test the wheel and readjust both adjuster until following standard achieved.

Requirement :
1. When handle pull up 3 to 4 notches both wheel are lock
2. When handle released both wheel are free and cam plate in original position.
3. Brake Pipe Connector and Bolt Should be tightened to spec

brake pipe connector Retaining

固定螺栓 bolts

1) 、 Brake line fitting ：

at the ECU module M10X1 、 M12X1, torque is(16±2)Nm
at other position, M10 torque (17~19 ） Nm ， M12 torque (22~24)Nm.
2) 、 Torque of ECU bolt is （ 8±2 ） Nm.

Notes about bleed brake system

1. If the ABS module is dry do not turn on the power of ECU when bleeding;
If the module is wet, turning the power on or off is allowed
2. follow the sequence of the wheel bleed order:
LH rear -- LH front -- RH front -- RH rear
3. Using diagnosis tool to execute bleeding operation refer to service manual
Common Fault of The Brake System:

1 、 Brake pedal is too soft or hard

a1 、 there is air inside the brake pipe
a2 、 brake gap problem or whether the shoe lining failure (check the fit degree)
b1 、 vacuum booster (one-way valves, vacuum tube, diaphragm)
b2 、 greasy dirt brake rotor or drum
2 、 Brake drag
1 、 vacuum booster interior jam
2 、 brake cable not proper set
3 、 brake return spring failed ( rear brake )
4 、 wheel cylinder internal seizure ( front caliper 、 rear brake)
5 、 master pump return fluid unsmooth
6 、 other mechanical failure (rotor warp, etc.)
3 、 Brake noise
1 、 check interfering with other component
2 、 rotor, drum and friction material hard spots
Common Fault repair:

1.General diagnosis and repair techniques on brake system can be applied to

Tunland brake system. Start with simple basic check (such as fluid level, leaks,
worn out or distorted components etc.)

2. Check caliper twin cylinder, pads and dust boots

3. ABS system failure has to be checked by scan tool. Cause no flash codes as
previous Foton vehicle.

4. Before troubleshooting ABS problem make sure all the wiring and sensors are
correct.