2006 GREAT WALL PEGASUS brake

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 caplower tension springupper 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)