2006 GREAT WALL SAFE wheel

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-26
Rear brake
Element figure
wheel-brake cylinder cluster
pressure spring drag rod
self clearance-
adjusting bracing
wireparking brake arm
flat washer
split pinbrake shoe gear
return spring
parking brake push plate
push-plate spring back brake
shoe
self clearance-
adjusting toggle
tension spring
brake drum
clearance adjuster
pressure spring seatpressure 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. DrBraking System
Rear Brake (Dr)

Parts that cannot be reused after being used

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-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-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)

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)