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

(38
50)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)

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)

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)

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)

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)N
m

(d)

Mount the caliper bracket on the steering knuckle and

screw up the bolts according to the specified torque.

Fastening torque

123N
m.

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

123N
m

2.

Mount the brake pads;

3.

Connecting the brake pipeline;

Use the open spanner to connect the pipeline.

Fastening torque

(21 
 1)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: 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)

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)

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)

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)

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

(16
20)N
m

(c) Connect the brake pipeline on the wheel-brake cylinder.

Fastening torque

18N
m

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

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)

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)N
m

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)