2006 GREAT WALL PEGASUS brake

BR-35
4. Tear down the front brake shoe:
(a)Tear down the tension spring from the front brake shoe;
(b) Tear down the pressure spring cap of brake shoe, the
pressure spring and claming pin.
(c) Tear down the lower tension spring from the front shoe
and the shoe pads.
(d) Tear down the lower tension spring from the rear shoe.
5. Tear down the rear brake shoe:
(a) Tear down the shoe pressure spring cap, pressure spring
and claming pin.
(b) Tear down the upper tension spring from the shoe pad.
(c) Tear down the rear brake shoe and the clearance adjuster.
(d) Tear down the parking brake bracing wire from the brake
shoe.
6. Tear down the clearance adjuster from the rear brake shoe:
(a) Tear down the clearance-adjusting spring.
(b) Tear down the clearance adjuster.
Braking System
Rear Brake (SF)

BR-36
7. Tear down the toggle plate and the brake lever:
(a) Tear down the open retainer ring;
(b) Tear down the toggle plate;
(c) Tear down the pin clip;
(d) Tear down the brake lever.
8. Tear down the wheel-brake cylinder:
(a) Tear down the brake pipeline. And block the pipeline
with a clean cork.
(b) Tear down the two bolts to take apart the wheel-brake
cylinder.
9. Tear down the following parts:
(a) Two dust covers;
(b) Two pistons;
(c) Two piston cups
(d) Spring. Braking System
Rear Brake (SF)

BR-37
Check and Repair the Brake Parts
1. Check the disassembled parts;
Check the disassembled parts to see whether there is abrasion,
rust or damage.
2. Measure the inner diameter of the brake drum;
Inner diameter
295.0mm
Max diameter
297.0mm
3. Measure the thickness of brake shoe liner;
Standard thickness
6.5mm
Min thickness
1.5mm
In case the thickness of brake shoe liner is less than the min
thickness or there is uneven abrasion, change the brake shoe.
Remark: if either brake shoe is required to change, all rear
brake shoes shall be changed to maintain the even braking
properties.
4. Check the brake shoe liner and the brake drum to see
whether there is close contact;
If there is poor contact between the brake shoe liner or brake
drum, repair or change the brake shoe cluster with the grinding
devices. Braking System
Rear Brake (SF)

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-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