GREAT WALL SAFE 2006 Service Manual

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.

SR-1
Notice .......................................................................... SR-2
Troubleshooting .......................................................... SR-2
Inspection on Vehicle .................................................. SR-3
Steering Column ......................................................... SR-4
Manual 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 mechanismInflate 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 damageInflate 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 playFront wheel bearing wear
Steering drive shaft yoke wear
Lower swing arm ball head wear
Steering gear joint wear
Steering gear unsuitable adjustment or damageChange 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-3Steering 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-4Steering 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 shaftupper part of steering column
50
5
universal cardan joint
dust cap
fixed support seat