Brake--Front brake assembly

Front brake assembly

Overhaul

1. Disassemble front wheels.

2. Discharge brake liquid.

Note: do not spill the brake liquid on paint  surface of automobile body, if having, wash it cleanly.

3. Disassemble brake branch pump assembly.

(a) Disassemble the bolts and gaskets of brake hose joint on

brake branch pump, then disassemble brake hose.

Hint: the gasket has two types: two sheets type or one

type.

(b) Fix sliding pin of cylinder body to disassemble two bolts.

4. Disassemble brake block of front wheels.

(a) Disassemble brake block with muffle gasket.

(b) Disassemble muffle gasket from every brake block.

5. Disassemble support sheet of brake block.

6. Disassemble sliding pin of brake branch pump.

Disassemble sliding pin on branch pump bracket.

7. Disassemble dustproof cover on brake branch pump.

Disassemble two dustproof covers from brake branch pump

of disk.

8. Disassemble left front brake branch pump.

Disassemble two bolts and brake branch pump bracket.

9. Disassemble dustproof cover of branch pump.

Use screw driver to disassemble oil seal loop and dustproof

cover.

10. Disassemble the piston of brake branch pump.

(a) Put a cloth or similar  thing between piston and branch pump.

(b) Use compressed air to disassemble piston from branch

pump.

Warning: when using compressed air, do not put your

finger at the front of piston.

Note: you could not be splashed by brake liquid.

11. Disassemble oil seal of piston.

Use screw driver to disassemble oil seal of piston from branch

pump.

12. Disassemble exhaust bolt of branch pump.

Brake branch pump

Dustproof cover

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Brake--Front brake assembly

13. Check the brake branch pump and piston

Check whether there is rust or scratch in cylinder of branch

pump and piston.

14. Check the thickness of brake block

Use rule to measure the thickness of brake block.

Standard thickness: 11.00mm

Minimal thickness: 1.0mm

15. Check support sheet of brake block

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Confirm the support sheet could rebound enough without any distortion, crack or abrasion, and it has

removed rust, dust and sundries completely.

16. Check the thickness of brake disk

Use centimeter to measure the thickness of brake disk.

Standard thickness: 25.00mm

Minimal thickness: 23.0mm

17. Disassemble front brake disk

(a) Make a mark on corresponding position of brake disk and shaft hub.

(b) Disassemble brake disk.

18. Assemble brake disk

Hint: choose the position with minimal terminal run-out quantity to assemble brake disk.

19. Check the terminal run-out of brake disk

(a) Lock the brake disk temporarily with shaft hub nut.

Torque: 103 

± 

± 

± 

± 

± 10 N⋅⋅⋅⋅⋅m

(b) Use centimeter to measure the terminal run-out of brake

disk on the position with 10mm apart from the exterior edge

of brake disk.

Maximal run-out quantity: 0.05mm

(c) If terminal run-out of brake disk exceeds or equals to maxi-

mal value, firstly, check the axial clearance of bearing, then

check the terminal run-out of shaft hub, if they are both

normal, adjust the terminal run-out of brake disk to eligible

value or use turning motor to turn terminal surface of brake

disk.

20. Lock exhaust bolt temporarily

Lock exhaust bolt temporarily on front brake branch pump.

21. Assemble oil seal of piston

(a) Spread lithium soap base glycol lubricating grease on new oil seal of piston.

(b) Assemble oil seal of piston on brake branch pump.

Note: do not force piston to assemble in branch pump compulsively.

22. Assemble piston of front brake branch pump

(a) Spread lithium soap base glycol lubricating grease on the piston.

(b) Assemble piston on brake branch pump.

Note: do not force piston to assemble in branch pump compulsively.

Brake--Front brake assembly

23.Assemble dustproof cover of branch pump..

(a) After spreading lithium soap base glycol lubricating grease

on new dustproof cover of branch pump, assembling it in

brake branch pump.

Hint: dustproof cover should be assembled in branch

pump firmly.

(b) Use wrench to assemble fixing loop.

Note: do not damage dustproof cover.

24. Assemble brake branch pump bracket.

Use two bolts to assemble brake branch pump bracket.

Torque: 106 

±±±±± 10 N⋅⋅⋅⋅⋅m

25. Assemble dustproof cover of brake branch pump

bracket.

(a) Spread lithium soap base glycol lubricating grease on new

dustproof cover.

(b) Assemble two dustproof covers in front brake branch pump

bracket.

26. Assemble sliding pin of front brake branch pump.

(a) Spread lithium soap base glycol lubricating grease on the

surface of sliding part and sliding pin.

(b) Assemble two sliding pins in front brake branch pump

bracket.

27. Assemble support sheet of brake block.

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28. Assemble brake block.

Note: when changing brake block, muffle gasket should be changed with brake block at the same

time.

(a) Spread brake lubricating grease on both sides of every muffle gasket.

(b) Assemble muffle gasket on every brake block.

(c) When assembling inner brake block, abrasion indicator should face the upside.

Note: do not attach oil dirt or lubricating grease on the surface of brake block and brake disk.

29. Assemble brake branch pump assembly.

(a) Use two bolts to assemble brake branch pump.

Torque: 34 

±±±±± 3N⋅⋅⋅⋅⋅m

(b) Use joint bolt to assemble new gasket and brake hose.

Torque: 30 

±±±±± 3N⋅⋅⋅⋅⋅m

Hint: Gasket has two types: two sheets type and one type.

Bracket soft pipe should be assembled in localizing hole of branch pump firmly.

30. Add brake liquid in storage tank.

31. Discharge the air in brake main pump.

32. Discharge the air in brake pipeline.

33. Check the liquid level of storage tank.

34. Check whether the brake liquid leaks.

35. Assemble front wheels.

Torque: 103 

±±±±± 10 N⋅⋅⋅⋅⋅m

Brake--Rear brake assembly

Rear brake assembly

Overhaul

Hint: overhaul procedure for right side is same as the left side.

1. Disassemble rear wheels.

2. Discharge brake liquid.

Note: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly.

3. Disassemble brake block of rear wheels.

(a) Disassemble fixing clamp of anti-vibration spring.

(b) Disassemble two guide pins of brake block and brake block

with muffle gasket.

(c) Take down muffle gasket from every brake block.

4. Disassemble left rear brake branch pump.

(a) Disassemble the joint, bolt and gasket of brake hose of brake

branch pump, then disassemble brake hose.

Hint: gasket has two types: two sheets type and one

sheet type

(b) Disassemble two bolts and brake branch pump.

5. Disassemble the bushing of brake branch pump.

Disassemble two bushings from brake branch pump.

6. Disassemble dustproof bushing of rear brake.

Disassemble three dustproof bushings.

7. Disassemble dustproof cover of branch pump.

Use screw driver to disassemble fixing loop and dustproof cover.

8. Disassemble the piston of brake branch pump.

(a) Put a cloth or similar thing between the piston and branch

pump.

(b) Use compressed air to disassemble piston from branch

pump.

Warning: when using compressed air, do not put your

fingers at the front of piston.

Note: do not let brake liquid splash on you.

9. Disassemble oil seal of piston.

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