2006 GREAT WALL DEER Service Manual

BR-38
Assembly of Rear Brake
left wheel
right wheelforward forward
1. Assemble the wheel-brake cylinder:
(a) Coat moderate lithium soap base glycol grease on the
piston cup.
(b) Assembly the wheel-brake cylinder

Mount the two piston cups on two pistons

Mount the two dust cover on two pistons.

Encase the spring and the two pistons in the wheel
cylinder body.
Remark: assembly correctly according to the direction shown
in the drawing.
2. Mount the wheel-brake cylinder:
(a) Mount the wheel-brake cylinder on the rear bottom plate
with two bolts.
Fastening torque
(6.5
10)N

m
(b) Connect the brake pipeline on the wheel-brake cylinder.
Fastening torque
(18+2)N

m
3. Coat the lithium base grease on the following parts:
(a) Hex convex platform where the bottom plate contacts
with the brake shoe.
(b) Two ends of support brocks
(c) Contact position where the piston and the shoe rib.
Remark: Do not pollute the friction pads. Braking System
Rear Brake (SF)
remark: assemble the component elements in the direction shown in the drawing;

BR-39
(c) Self adjusting screw arbor thread;
(d) Contact position where the self-adjusting screw sleeve
and the brake shoe.
4. Mount the parking brake lever and the toggle plate
(a) Mount the parking brake lever and lock it with a new pin.
(b) Mount the toggle plate and a new open retainer ring.
5. Mount the adjuster on the rear brake shoe:
(a) Mount the adjuster;
(b) Mount the clearance-adjusting spring;
6. Mount the rear brake shoe:
(a) Mount the brake bracing wire on the parking brake lever;
(b) Mount the tension spring on the rear brake shoe;
(c) Encase the rear brake shoe in such way that the end shoe
is inserted in the wheel-brake cylinder.
(d) Mount the brake shoe pressure spring, pressure spring
cap and the claming pin.
Notice: Do not let the oil or lubricant touch the brake
shoe. Braking System
Rear Brake (SF)

BR-40
7.Mount the front brake shoe:
(a) Mount the lower tension spring between the front shoe
and the back shoe.
(b) Mount the front brake shoe in such manner that the end
shoe is inserted in the wheel-brake cylinder, and mount
correctly the adjuster.
(c) Mount the pressure spring, pressure spring cap and
claming pin.
Notice: Do not let the oil or lubricant touch the brake
shoe.
(d) Mount the upper tension spring.
8. Check the operation of self-adjusting mechanism.
(a)Move the parking brake lever of rear brake shoe forward
and backward as shown in the drawing, check the self-
adjusting screw arbor to see whether it can rotate or not,
if not, check the rear brake to see which part has problem.
(b) Adjust the adjuster length and shorten it as can as possible.
(c) Mount the brake drum.
(d) Drag the parking brake lever to the max distance until no
quack-quack is heard. Braking System
Rear Brake (SF)

BR-41
9. Check the clearance between the brake shoe and the
brake drum:
(a) Tear down the brake drum.
(b) Measure the inner diameter of brake drum and the outer
diameter of brake shoe, then Check the difference of the
two diameters to see whether it falls within the standard
clearance range.
Shoe clearance: 0.6mm
If it is not correct, check the parking braking system.
10. Mount the brake drum and rear wheel;
Fastening torque
(145
10)mm
11. Fill the liquid container with brake liquid and exhaust
air in the braking system.
12. Check to see whether there is leakage of brake liquid Braking System
Rear Brake (SF)

BR-42Braking System
Load Sensing Proportion Valve
Load Sensing Proportion Valve
Element figure
Inspection on and Adjustment of hydraulic
pressure
1. Adjust the load on rear shaft
Load on rear shaft (including the vehicle weight): 800kg
2. Mount the load sensing proportion valve instruments
(SST) and exhaust the air.
location plate
valve bracket
load inductive valvebraking hose bracket
flat washerflat washer
load inductive spring
assembly
inductive spring bracketclaming head I
claming head II

split pin
shaft bush

Parts that cannot be reused after being usedsnapping ring

BR-43Braking System
Load Sensing Proportion Valve
3. Check the rear brake pressure on the condition that
the front brake pressure increases to 7,845kPa
Rear brake pressure: (4,315
490)kPa
If the brake pressure is incorrect, adjust the hydraulic pressure.
4. Adjust the hydraulic pressure if necessary:
(a) Adjust the length of claming head II.
When lengthen the A distance, the rear brake pressure; if A
distance is shortened, the rear brake pressure reduces.
Initial adjustment: 78mm
Adjust range: (72-84)mm
(b) In case no even brake pressure is obtained after adjusting
the claming head, raise the valve or move it downward.
If the valve moves forward, the rear brake pressure will reduce;
if the valve moves downward, rear brake pressure will increase.
(c) Screw up the nuts.
(d) Adjust the length of claming head II again.
If it is unsuitable after re-adjustment, change the valve.
Disassembly of load sensing proportion valve
1. Tear down the claming head II from the bracket;
2. Tear down the load sensing proportion valve cluster:
(a) Tear down the brake pipeline from the valve with SST.
A
SST
kPakPa

BR-44Braking System
Load Sensing Proportion Valve
(b) Tear down the mounting bolts of valve bracket, and load
sensing proportion valve cluster.
Mount of Load Sensing Proportion Valve
1. Mount the load sensing proportion valve cluster on the
frame.
2. Connect the claming head II with the bracket:
(a) Mount the claming head on the load inductive spring;
(b) Adjust the spacing A.
Initial adjustment: 78 mm;
(c) Mount the claming head II on the claming head bracket
3. Connect the brake pipeline;
Connect the brake pipeline with SST.
Fastening torque

Dr SF
(18
2)N
m
SL SK SY SJ
(19
1)N
m
4. Adjust the rear shaft load
5. Adjust the valve:
(a) When drag downward the load inductive spring, the
valve piston shall move downward smoothly.
(b) When mount the valve body, the valve piston shall touch
the load inductive sensing spring lightly.
(c) Screw up the mounting nuts of valve body.
SST

BR-45Braking System
Load Sensing Proportion Valve
6. Exhaust the air in braking system
7. Check and adjust the hydraulic pressure of load
sensing proportion valve.