Great Wall Pegasus (2006 year). Instruction - part 16

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 wheel

forward

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-42

Braking 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 valve

braking hose bracket

flat washer

flat washer

load inductive spring

assembly

inductive spring bracket

claming head I

claming head II

 split pin

shaft bush

  Parts that cannot be reused after being used

snapping ring

BR-43

Braking 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

kPa

kPa

BR-44

Braking 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-45

Braking System

 Load Sensing Proportion Valve

6.

Exhaust the air in braking system

7.

Check and adjust the hydraulic pressure of load

sensing proportion valve.

SR-1

Notice .......................................................................... SR-2

Troubleshooting .......................................................... SR-2

Inspection on Vehicle .................................................. SR-3

Steering Column ......................................................... SR-4

Instruction Steering Gear ................................................. SR-9

Power Steering ............................................................ SR-11

General Introduction ................................................ SR-11

Inspection on vehicle ............................................... SR-13

Power Steering Oil Pump ........................................ SR-16

Power Steering Gear ............................................... SR-18

Steering linkage .......................................................... SR-20

SR

  Steering System

Page

SR-2

Notice

The parts change should be conducted correctly because

any error will affect the properties of steering system, or lead

to accidental or damage when driving.

Troubleshooting

Trouble

Causes

Inspection items

Unsuitable tire inflation

Insufficient lubricant

Over-large inclination

Steering gear joint wear

Lower swing arm ball head wear

Steering column seize-up

Steering gear unsuitable adjustment or damage

Power steering conveyer looseness

Over-low liquid level in oil cup of steering pump

Failure in power steering mechanism

Inflate the tire to specified pressure

Lubricating the hanging devices

Check the Alignment of Front Wheel

Change the Steering gear joint

Change the lower swing arm ball

head;

Check the steering column

Adjust or repair the gear.

Adjust the conveyor.

Check the steering pump oil cup

Check the power steering devices

Poor returning

Unsuitable tire inflation

Insufficient lubricant

Incorrect wheel alignment

Steering column seize-up

Steering gear unsuitable adjustment or damage

Inflate the tire to specified pressure

Lubricating the hanging devices.

Check the Alignment of Front

Wheel

Check the steering column

Change the steering gear.

Over-large play

Front wheel bearing wear

Steering drive shaft yoke wear

Lower swing arm ball head wear

Steering gear joint wear

Steering gear unsuitable adjustment or damage

Change the front bearing

Change the steering drive shaft

Change the swing arm ball head

Change the steering gear joint

Change the steering joint

Abnormal noise

Steering drive lever looseness

Steering gear joint wear

Steering gear unsuitable adjustment or damage

Oil lack or poor sealing of steering machine.

Tighten the steering drive lever

Change the steering gear joint

Change the steering gear

Add the oil or change the sealing

washer Steering system inspection

on vehicle.

Steering System

 Notice and Troubleshooting

Difficulty in steering

SR-3

Steering System

 On-vehicle Inspection

max play

On-vehicle Inspection

Steering wheel play

1.SR-18Check to see whether the steering wheel play is

correct;

Park the vehicle stably and align the tires in correct direction,

press the steering wheel with finger and swing it in left and

right direction. The play should not exceed the max play.

(Max play) 

6
(Dr SF)

If the play is nor correct, adjust or repair the steering wheel as

requirement.

2.

Adjust the steering wheel play:

(a)

Align the wheel forward precisely;

(b)

Loosen the locking nuts of steering gear;

(c)

Rotate the adjusting screws of steering gear clockwise to

reduce the steering wheel play, while contrarotate the

adjusting screws to increase the steering wheel play.

Remark: screw the adjusting screws and enlarge the play a

little each time to check the adjusted play.

3.

Check to see whether there is steering inconvenience

Rotate the steering wheel by half round in right and left

direction to check whether the play is correct, and whether the

wheel runs smoothly or any seize-up in its running.

4.

Fix the adjusting screws and fasten the adjustable nut.

Oil level height

Check the oil level height in the steering gear housing.

Oil level height: flush with the filler opening.

If there oil is insufficient, add the gear oil and check to see

whether there is oil leakage.

SR-4

Steering System

 Steering Column

Steering Column

Element figure of  non-adjustable steering column

Dr

SL SK SY

upper part of

steering column

steering drive shaft

30

 2

N

m

specified torque

steering drive shaft

upper part of steering column

50

 5

universal cardan joint

dust cap

fixed support seat

SR-5

Steering Column

Element figure of adjustable steering column

Steering System

 Steering Column

Dr SF

upper part of steering column

universal cardan joint

steering drive

shaft

upper part of steering column

steering drive shaft

universal cardan joint

universal cardan joint

steering column

SL SK SY

SJ