SKODA 120 LSE 1980 Workshop Manual

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Fig.9./1- Hydroulic Broke System Diogrom
'l - Broke f luid tonk
2 -
Moster cylinder
3 -
Broke booster (on
SfOOn 120 LS cors)
4 -
Moster cylinden supply line
5 -
Moin front-broke circuit line
6 -
Front brake distribution system
7 -
Front broke mechonism
8 -
Moin reor-broke circuit line
9 -
Reor broke distribution system
10 -
Reor broke mechonism
I on
cors fitted
11 -
Broke booster vocuum line
I with
broke
J booster
12 -
Suction line
connection
Fig.9.1/1 -
Reor Broke AssemblY
134 C
r
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Broke
Shoes ond Broke Drums
When refitting
o broke shoe with o portiolly
worn lining moke sure thot it hos o thickness
sufficient to lost till the periodic
inspection
(ofter every 20,000 kilometres). The new lining
is 5 mm thick. When it is worn down to 1.5
to 'l
mm (4
to 3.5 mm when meosured
with the
shoe), the broke shoe hos to be reploced
with
o new.or
o reconditioned
shoe with glued-on
new lining. Be sure to reploce
the respective
broke shoes in both wheels to preserve
o uni-
form broking effect.
Speciol glues or cements
ond hordening ot
high temperotures
ore required when relining
the broke shoes so thot this
iob con
be done in
speciolized repoir shops
only. For informotion,
opply to the broke monufocturer -
Autobrzdy
Not. Corp., Joblonec
nod Nisou.
Broke drums are grey
cost-iron costings. Their
unequol weor
con be rectified
by mochining to
o 231 mm diometer.
No tool morks must be left
on their surfoce
which hos to be perfectly
smooth. The olignment deviotion
ond mochin-
ing toleronce should
not exceed 0.1 mm. The
moximum permissible weor is up Lo 232
mm in
diometer.
Only broke drums
with on identicol
diometer
ore permitted
to be mounted on one ond the
some oxle.
9.2 FRONT BRAKE
ASSEMBLY
Disnrontling ond Reossembly
1. Detoch
the broke fluid supply piping
from
the broke. Absolute cleonliness is o must.
Otherwise dirt ond foreign
motterwill penetrote
into the piping.
2. Renrove bolts lrolding
down the broke yoke
crnd lift owoy rlre broke
ossembly.
3. Use the MP 6-132 gouge
to set correctly
the broke (new
or repoired)
on reinstollotion.
4. Select the shims required
to fill the gop
between the end of the gouge
ond the foce of
the fostening lug.To position
correctly the
broke, insert shims
between the fostening lugs
cnd yokes. You con, however,
meosure direct
the distonce
between the fostening
lug ond the
trroke disk
ond set this distonce
in complionce
with Fig. 9.211 by odding pocking
pieces
to the
shim pock.
5. Using the respective
copscrews ond spring
'.^roshers, bolt down the yoke
to the lugs.
6. Attoch the supply hoses ond bleed
the
broke.
Replocing the Brake
Disk
A worn brol disk con be reconditioned by
grinding it to o thickness
of 7.5 mm. lf necess-
cry, reploce it with o new one 9 mm thick. The lowest
limit of thickness
of o still usoble
broke disk is 6.5 mm. The
moximum permissible
run-out of the friction surfoce is
0.15 mm.
1. After hoving lifted owoy
the broke os-
sembly, remove the wheel hub
ond then the
broke disk. 2. Reossemble the broke disk
with the wheel
hub using copscrews with spring
woshers.
3. Top
rrp or chonge the lubricont
in the
wheel
hub beorings ond reinstoll the broke ossembly
Replocing Broke Pods
The overoll thickness of o broke pod
with
new lining is 15 mm. When worn down to 7 mm
(with the lining 1.5 mm thick), the pod
is
unusoble.
Alwoys reploce
broke pods
on both ends of
the oxle of the some time so
thot their weor is
uniform. With regord to the coefficient of fric-
tion, they hove to be of the some
type ond
rnoke.
1. Suck off the hydroulic fluid from the tonk
so thot it is only holf filled.
2. Remove cotter pins
ond lift
owoy the broke
lining cover.
3. Remove the friction pod,
cleon thoroughly
the covities of the yokes, piston
ports,
ond dust
boots.
4. Fit the MP 6-134 force-off lever over the
broke disc ond drive the pistons
into the
cylinder bottoms by the presswe
of levers.
5. Ploce o new friction pod
into the broke
ossembly moking sure thot the clomp of the
thrust plote
fits into the collor of the piston
foce.
Fig.9.2l1- Front Wheel Broke Mechonism
ond Mounting (setting)
Dimensions
1 -
Broke disk
2 -
Broke
3 -
Shims
A -
Broke setting climension -
18.7+O.2
136

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Reossemble the
pressure-relief
following order: dust cup, spring,
ond seol. Nicks ond burrs
ore opt to domoge
the dust
boot ond prevent
its perfect
odhesion to the
cylinder. Every boot must be odequotely pre-
stressed (topered)
so thot its seoling edge con
be in permonent
contoct with the cylinder sur-
foce. A decreosed prestress
signols excessive
weor of the dust boot or its fotigue. For the
cleoning ond lubricotion of working ports,
see
the instructions in
Chopter 9.3.
9.5 FRONT BRAKE WHEEL CYLINDERS
Wheel cylinders ore ossemblies formed
by
one cylinderwith the yoke
ond onother cylinder
with the f longe ond occessories. Fig. 9.5/1
shows the loyout. For cieoning ond lubricotion
of the working surfoces, see the informotion
in Chopter 9.3.
Dismontling
1. After hoving removed the broke pods,
disconnect ond lift owoy the interconnecting
piping, cnd then remove f our copscrews to
seporote the cylinder with the yoke
from the
flonged cylinder.
2. Pull off the retoining
ring of the dust boot
ond lift owoy the dust boot.
Connect o com-
pressed oir supply (or
the broke moster cylinder)
ond use it to force the piston
out of the
Fig. 9.5/1 -
Front Broke Wheel Cylinder c/w
Broke Pods
volve in the
spring plote,
Fig. 9.312 -
Secondory Piston Cup Mounting
Fixture for dio. 12 mm
Moster Cylinder
(1 -
guide bush, 2 -
clomping ring)
Fig. 9.3/3 -
Secondory Piston Cup Mounting
Fixture for dio. 22
mm Moster Cylinder
(1- guide
bush, 2 -
clomping ring)
9.4 REAR BRAKE WHEEL
CYLINDER
'l-he wheel cylinder requires procticolly
no
servicing. Whenever removing
the broke drums,
exomine the rubber dust boots.They hove
to be
perfectly tight, flexible,
ond undomoged. When
replocing them, exomine the inner surfoce of
the wheel cylinder ond the surfoce
of the piston.
Fig. 9.4/1 -
Sectionol View of Wheel
Cylinder
138

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I
I
T
!
(
(
t I
t
t
t I
'l
(
r
o cc
fold
ot the moment of
the opplicotion of the
brokes, ond led
through o rubber hose (tube)
to
the booster.
Removol ond Refitting
The broke booster is held down on the pedol
brocket by nuts ond spring
woshers. The lug of
the control volve press
button connects it with
the broke pedol,
on which it is secured by o re-
toining ring. These
mounting ports
or the con-
nections of the vocuum supply
ore to be hondl-
ed only when removing
or refitting the broke
booster.
However, we odvise you
to hove this
iob done
in o speciolized
repoir shop properly
instructed
by the broke
monufocturer. All rubber ports (in
the terms of current mointenonce,
this is
procticolly the seol of the press
button control-
ling the moster cylinder)
must be protected
from the effects of the broke fluid or other
lubriconts. Use petrol
for cleoning the rubben
ports.
Adiustment 1. Adiust the cleononce
between the broke
booster press
button ond the cylinder piston
whenever the moster
cylinder or the'broke
booster ore reploced,
or whenever there is ony
doubt concerning
the correctness
of the os-
sembly of the moster cylinder
with the broke
booster. Meosure the distonce between the
cylinder bottom recess
ond the cylinder flonge
nroting surfoce os well os the length of the
press button protruding
over the moting surfoce
of the booster.
Compore the meosurings
ond
odiust the length of the press
button by rototing
its threoded
end to obtoin o cleoronce of 0.5 to
1 mm between the press
button ond the piston.
Still better, you
can use special
tools Mp6.
'14'lA.
Fit it on the
moster cylinder, push
its spindle into the cylinder till its rounded
end
rests ogoinst
the piston,
ond lock it in this po-
sitio-n with the respective
retoining screw.
Apply
the fixture to the booster
ond rotote the boostei press
button so thot it
iust touches the
lower
flot port
of the fixture spindle.
2. lf it is necessory
to level
the broke pedol
with the clutch pedol,
odiust the length
of the
contnol volve press
button lug.
Remove the broke
booster from the pedol
brocket, slip off the collor (cup),
connect the
booster with the pedol,
ond refit it tempororily
to the brocket.
Now rotote the hexogon on the
threods of the lug till both the clutch ond broke
pedol ore level. Remove once more the booster
from the pedol
ond pedol
brocket, neinstoll the
collor (cup),
ond complete the f inol reossembly.
9.7 BRAKE FLUID TANK, PIPING AND HOSES
Tonk ond Filling Hose
The broke fluid tonk is held in position
in its
brocket by o slip-over
clomp. Speciol rubber
hoses connect it with the broke ond clutch
moster cylinders.
Hose clips ore used to secure
the hoses on the tonk outlet sockets.
Both the
side ond centre outlet of the tonk ore con-
nected to the bnoke moster cylinder, the third
outlet being connected to the clutch moster
cylinder (see Fig. 12.111).
Pressure Piping ond Hoses
The rigid port
of the hydroulic line consists
of speciol steel pipes.
Their connections with
other ports of the line ore seoled off by clomp-
ing on the conicol surfoces-
lf these conicol surfoces
become domoged,
remove them ond form new ones by floring the
pipes. To do this, use the coulking holder,
type
MP 9-151. Clomp the pipe
in the holder so thot
it is level with its upper edge ond flore the pipe
with c coulking chisel. The holder is designed
to be clomped in o vice.
The holder
hos two drilled holes of 5 ond
6 mm in diometer so thot it con be used olso for
repoirs of pipes
of the clutch line. For dio.
5 mm holes, use the MP 9-152 ond for dio. 6 mm
holes, the MP 9-153 coulking chisel.
The flexiblepqrt
of the hydroulic line consists
of speciol hoses.
When fitting them to the reor
wheel cylinders, turn them in o position
which
will prevent
their contoct with ony ports
of the
cor in both extreme positions
of the cor sus-
pension. This is why the nipples ot the reor
wheels ore inclined
downword through on
ongle of 30 degrees from
the horizontol plone.
9.8 HAND BRAKE
The hond-broke
lever between the front seots
controls the tie-rod which octuotes the rocker
(see Fig.9.8/1). Cobles connected
to the rocker
Fig. 9.612
-
Broke Booster Press
Button
Adiusting Fixture
MP6 141A tx r5?2
140

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