Great Wall Pegasus (2006 year). Service Manual — part 15
BR-19
4.
Mount the sliding liner, sliding sleeve dust cover and
sliding sleeve.
(a)
Encase the sliding liner and sliding sleeve dust cover in
the wheel-brake cylinder.
(b)
Ensure the sliding sleeve dust cover in the ring groove of
wheel-brake cylinder hard.
(c)
Encase the sliding sleeve in the sliding sleeve dust cover.
(d)
Ensure the sliding sleeve dust cover in the ring groove of
sliding sleeve.
Mount of Brake Calipers
1.
Mount the brake pad;
2.
Mount the wheel-brake cylinder:
(a) Mount the wheel-brake cylinder;
(b) Mount and tighten the two assembling bolts (the bolts
shall be coated with the thread locking sealing agent).
Fastening torque
(3850)N.m
3.
Connect the brake pipeline.
Connect the brake pipeline with the calipers.
Fastening torque
(21 2)N.m
4.
Observe the height of brake liquid level and, if
necessary, add in the brake liquid and exhaust the air
in braking system.
Notice: prevent the brake liquid from spraying on the
brake disc when exhausting air.
5.
Check to see whether there is leakage of brake liquid.
Braking System
Front Brake (Dr)
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BR-20
Front Brake
Element figure
spring gasket12
123
separation pads
silent pad
brake pad
brake caliper
brake pad snapping ring
guide pin lock spring
sealing ring
guide pin
dust cover steel gripping hoop
piston dust cover
piston
brake disc
: fastening torque
N
M
Change of Brake pad
Remark: In case there is a continuous screaming from the front
wheel when braking the vehicle during driving, check the
alarm pad for friction limit for brake pad. If there is friction
trace on the alarm pad with the brake disc, change the brake pad
1.
Disassemble the front wheel;
2.
Check the thickness of friction material of brake pad.
Check the thickness of friction material of brake pad, if it fails
to be within the specified range, change the brake pad.
Min thickness
2.0mm
SF
Braking System
Front Brake(SF)
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BR-21
3.
Disassemble the following parts:
(a)
Guide pin snapping spring;
(b)
Two guide pins;
(c)
Brake pad snapping ring
(d)
Two brake pads;
(e)
Two silent pads; and
(f)
Two separation pads
4.
Measure the thickness of brake disc.
(See BR-24)
5.
Measure the radial swinging of the brake disc.
(see page BR-24)
6.
Mount on the new brake pad;
(a)
Draw out a little brake liquid from the liquid container.
(b)
Press in the piston with the hammer lever and similar tool.
Remark: Only one brake pad of the same wheel can be changed
in one time so as to prevent the piston on the other face ejecting
out.
(c)
Mount two silent pads and two separation pads on the
new brake pad.
Remark: coat the brake oil for disc on the inner silent
pads.
(d)
Mount the brake pad with the worn limit alarm pad on the
inner side, while the other brake pad on the outer side.
Note: Pollution of oil stain or coat is not allowed on the
work faces of brake pad or brake disc.
7.
Mount the brake pad snapping spring;
Brake pad snapping spring shall be mounted at the lower
position;
Braking System
Front Brake(SF)
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BR-22
8.
Mount the two guide pins;
9.
Mount the guide pin snapping spring
Disassembly of Wheel brake Pump
1.
Disassemble the front wheel;í
2.
Disassemble the brake pipeline;
Tear down the brake pipeline with a container containing the
brake liquid.
3.
Disassemble the wheel-brake cylinder.
Tear down the two hex bolts and the wheel-brake cylinder.
4.
Disassemble the following parts:
(a)
Guide pin snapping spring;
(b)
Two guide pins;í
(c)
Brake pad snapping spring;
(d)
Two brake pads;
(e)
Two silent pads and
(f)
Two separation pads.
Braking System
Front Brake(SF)
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BR-23
Wheel-brake cylinder disassembly:
1.
Tear down the dust cover steel gripping hoop and the
dust cover.
Tear down the dust cover steel gripping hoops and piston dust
covers of the four wheel-brake cylinders with the screwdriver.
2.
Tear down the piston from the wheel-brake cylinder:
(a)
Prepare a wooden block with the dimensions as shown in
the drawing (which is used to support the piston)
(b)
Put the wooden block between the pistons and insert one
brake pad on one side of the wooden block.
(c)
Tear down the four pistons from the wheel-brake cylin-
der by using the compressed air.
Warning: do not put your fingers in front of the piston
when using the compressed air.
3.
Tear down the piston sealing ring.
Tear down the four piston sealing ring from the wheel-brake
cylinder with the screwdriver.
Check the front brake parts
1. Measure the thickness of brake pad liner;
Standard thickness
9.0mm
Min thickness
2.0mm
In case the liner is less than the min thickness or the liner is
worn unevenly, change the brake pad.
Braking System
Front Brake(SF)
mm
mm
mm
-------------------------------------------------------------------------------------------------------------------------------------------------------------
BR-24
2.
Measure the thickness of brake disc;
Standard thickness
20.0mm
Min thickness
18.0mm
If the brake pad is scraped, repair it; where the abrasion is
serious and its thickness is smaller than the min thickness,
change the brake disc.
3.
Measure the bounding value of the brake disc face;
Remark: the bearing is required to be verified in the suitable
adjustment before measuring.
Max face bouncing value: 0.11mm;
4.
Change the brake disc according to the requirement:
(a)
Tear down the hub and the brake disc. (see the paragraph
of front wheel hub)
(b)
Mount the new brake disc and screw up the connecting
bolts as the specified torque.
(c)
Mount the hub and brake disc assembly. (see the para-
graph of front wheel hub).
Fastening torque
(75 5)Nm
(d)
Mount the caliper bracket on the steering knuckle and
screw up the bolts according to the specified torque.
Fastening torque
123Nm.
Assembly of Brake-wheel pump
1.
Preparation
All parts shall be washed, dried and cleared away the alien
materials, and coat moderate rubber lubricant on the work
faces of piston, piston dust cover and rectangular sealing ring.
2.
Encase the piston sealing ring in the caliper body
Braking System
Front Brake(SF)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
BR-25
3.
Encase the piston in the caliper body.
4.
Encase the piston dust cover, dust cover steel-
gripping hoop in the caliper body.
Mount of Brake Calipers
1.
Mount the brake caliper and screw up the two
mounting bolts.
Fastening torque
123Nm
2.
Mount the brake pads;
3.
Connecting the brake pipeline;
Use the open spanner to connect the pipeline.
Fastening torque
(21 1)Nm
4.
Observe the height of brake liquid level and, if
necessary, add in the brake liquid and exhaust the air
in braking system.
Notice: avoid the brake liquid of spraying on the brake disc
when exhausting the air.
5.
Check to see whether there is leakage of brake liquid.
Braking System
Front Brake(SF)
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BR-26
Rear brake
Element figure
wheel-brake cylinder cluster
pressure spring drag rod
self clearance-
adjusting bracing
wire
parking brake arm
flat washer
split pin
brake shoe gear
return spring
parking brake push plate
push-plate spring
b a c k b r a k e
shoe
s e l f c l e a r a n c e -
adjusting toggle
tension spring
brake drum
clearance adjuster
pressure spring seat
pressure spring
front brake shoe
Disassembly of Rear drum-type Brake
Remark: if the braking torque of manual brake cannot satisfies
the braking requirement, it is suggested to check the thickness
of brake shoe liner, where the thickness is less than the min
thickness, change the brake shoe.
Min thickness
1.0mm
1.
Tear down the rear wheel;
2.
Tear down the brake drum;
Remark: in case the brake drum is not easy to tear down, the
following steps shall be adapted:
(a)
Tear down the clearance-adjusting hole; insert a screw-
driver in the brake bottom plate hole to prize up the
adjusting bolt inner tilt angle with the self-adjusting fork.
(b)
Use another screwdriver to adjust the adjusting bolt inner
tilt angle to loosen the clearance adjuster of brake shoe.
Dr
Braking System
Rear Brake (Dr)
Parts that cannot be reused after being used
-------------------------------------------------------------------------------------------------------------------------------------------------------------
BR-27
3.
Tear down the return springs of the two brake
shoes.
4.
Tear down the self-adjusting bracing wire, brake shoe
retainer ring, bracing wire guide seat and the self-
clearance adjusting toggle plate.
(a)
Press and push the self clearance-adjusting toggle plate to
teardown the bracing wire of self clearance-adjuster,
brake shoe retainer ring and bracing wire guide seat.
(b)
Take out the spring from the self clearance-adjusting
toggle plate to tear down the clearance-adjusting toggle
plate and the spring.
5.
Tear down the tension spring;
Tear down the tension spring with the pliers.
6.
Tear down the brake shoe, clearance adjuster and
parking brake push plate.
(a)
Tear down the pressure spring seat, pressure spring and
pressure spring drag rod.
(b)
Tear down the brake shoe, clearance adjuster and parking
brake push plate.
(c)
Tear down the bracing wire from the parking brake.
Braking System
Rear Brake (Dr)
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BR-28
7.
Tear down the parking brake arm;
Tear down the split pin with pliers to take apart the parking
brake arm.
8.
Take apart the brake pipeline from the wheel pump;
Tear down the brake pipeline and block the oil pipe with a clean
cork.
9.
Tear down the wheel brake pump;
Tear down the two bolts and the wheel-brake cylinder.
10. Tear down the following bolts and wheel-brake
cylinder parts:
(a)
Two piston rod;
(b)
Two dust cover
(c)
Two pistons
(d)
Two piston rubber bows
(e)
Spring.
Braking System
Rear Brake (Dr)
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BR-29
Check and Repair the Rear Brake Parts
1.
Check and test the disassembled parts;
Check the disassembled parts to see whether there is abrasion,
rust or damage.
2.
Measure the inner diameter of brake drum;
Standard inner diameter)
254.0mm
Mix inner diameter: 256.0mm
3.
Measure the thickness of brake shoe liner;
Standard thickness
5.0mm
Min thickness
1.0mm
In case the thickness of brake shoe liner is less than the min
thickness or there is uneven abrasion, change the liner.
Remark: if one of the brake shoes is needed to change, all of the
brake shoes are required to change so that the even braking
performance is maintained.
4.
Measure the brake liner and the brake drum to see
whether they contact closely;
If there is poor contact between the brake liner and the brake
drum, repair the brake shoe with the grinding devices, or
change the brake shoe cluster.
Braking System
Rear Brake (Dr)
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BR-30
Assembly of Rear Brake
remark: assemble the parts according to the
direction in the drawing;
left wheel
right wheel
forward
1.
Assemble the wheel-brake cylinder:
(a)
Coat moderate lithium soap base glycol grease on the
piston cup;
(b)
Assemble the wheel-brake cylinder:
Mount the two piston cups on two piston;
Encase the spring and two pistons in the wheel cylinder
body and
Mount the two dust covers
Remark: Assembly shall be conducted correctly according to
the direction shown in the drawing.
2. Mount the wheel-brake cylinder:
(a)
Use two bolts to fix the wheel-brake cylinder on the rear
bottom plate.
Coat moderate sealing glue (Glue 704) on the position where
the wheel-brake cylinder connects with the bottom plate.
Fastening torque
(1620)Nm
(c) Connect the brake pipeline on the wheel-brake cylinder.
Fastening torque
18Nm
3.
Coat the following parts with moderate lubricant that
resistant high temperature (do not pollute the friction
plates);
(a)
The upper plain of the hex convex platform where the
bottom plate connects the brake shoe;
(b)
Contact face of the brake shoe and the top lever of wheel
cylinder;
(c)
Contact face of the brake shoe with the support pin.
Braking System
Rear Brake (DR)
Assembly of Rear Brake
forward
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BR-31
(d)
Adjusting bolts
(e)
Contact position where the clearance adjuster and the
brake shoe.
4.
Mount the parking brake drag arm;
Mount the new split pin with pliers to mount the parking brake
drag arm.
5.
Mount the rear brake shoe:
(a)
Mount the parking brake bracing wire on the parking
brake drag arm.
(b)
Mount the rear brake shoe in such way that its end is
inserted into the cylinder rod. Encase the pressure spring
drag rod in the brake bottom plate and the brake shoe
assembly in turn and then insert it in the pressure seat ,
pressure spring, pressure spring seat, finally rotate the
pressure spring in place with the pressure spring fork.
6.
Mount the parking brake pull plate and the front brake shoe:
(a)
Mount the pull plate and the spring.
(b)
Mount the front brake shoe, of which, the end is inserted
in the piston rod, and mount the pull plate. Insert the
pressure spring drag rod in the brake bottom plate and
brake shoe assembly in turn, then encase it in the pressure
spring seat, pressure spring and pressure spring, finally
rotate the pressure spring in place with the pressure
spring.
7.
Mount the tension spring;
Mount the tension spring with pliers.
Braking System
Rear Brake (DR)
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BR-32
8.
Mount on the adjuster;
Poke the brake shoes with the screwdriver and then mount the
adjuster.
9.
Mount the brake shoe retainer ring, bracing wire of
guide seat, self clearance-adjusting bracing wire and
the return spring.
(a)
Mount the brake shoe retainer ring, then the front return
spring.
(b)
Mount the return spring ,and then mount the forward
return spring.
10. Mount the self-clearance toggle plate:
(a)
Mount the toggle plate bracing wire torsion spring on the
rear brake shoe.
(b)
Mount the clearance self-adjusting toggle plate and hook
It with the clearance-adjusting bracing wire.
(9)
Hook the self clearance-adjusting toggle plate with the
bracing wire torsion spring
11. Check the operation of self-adjusting mechanism.
(a)
Drag the clearance-adjusting bracing wire backward as
shown in the drawing, then release it. Check the clear-
ance-adjusting bolts to see whether it is rotating. If not,
check the rear brake to verify which part has problem.
(b)
Adjust the clearance adjuster to shorten its length as
possible as can.
(c)
Mount the brake drum
forward
Braking System
Rear Brake (DR)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
BR-33
12. Check the clearance between the brake shoe and the
brake drum:
(a)
Tear down the brake drum;
(b)
Measure the inner diameter of the brake drum and the
outer diameter of brake shoe to check whether the differ-
ence of the two diameters falls within the standard
clearance range.
Shoe clearance: 0.6mm
If it is not correct, check the parking brake system.
13. Mount the brake drum and the rear wheel; screw up
the nuts of rear wheel hub.
Fastening torque
(145 10)Nm
14. Fill the liquid container with brake liquid and exhaust
the air in braking system.
15. Check to see whether there is leakage of brake liquid.
Braking System
Rear Brake (DR)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
BR-34
Rear brake
Element figure
Parts that cannot be reused after using.
wheel-brake cylinder cluster
observation hole cork
claming pin
observation hole cork
front brake shoe
pressure spring cap
lower tension spring
upper tension spring
clearance adjuster
rear brake shoe
brake lever
toggle plate
open retainer ring
clearance-adjusting spring
brake drum
pressure spring
Disassembly of Rear Brake
1.
Check the thickness of the brake shoe liner:
Tear down the observation hole cork I and measure the thickness
of brake shoe liner through the observation hole. If the thickness
if less than the min thickness, change the brake shoe.
Min thickness
1.0mm
2.
Tear down the rear wheel.
3.
Tear down the brake drum;
Remark: if the brake cannot be tear down easily, the following
steps shall be adapted:
(a)
Tear down the observation hole cork II by inserting the
screwdriver in the hole of brake bottom plate, and poke
the toggle plate from the self-adjusting screw arbor.
(b)
Loosen the brake shoe clearance adjuster with another
screwdriver by screwing the self-adjusting screw arbor.
SF
Braking System
Rear Brake (SF)
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