torque GREAT WALL SAILOR 2006 Owners Manual

BR-20
Front Brake
Element figure
spring gasket12
123
separation padssilent pad
brake padbrake caliper
brake pad snapping ring
guide pin lock spring
sealing ringguide pin
dust cover steel gripping hoop
piston dust cover piston brake disc
: fastening torqueN
M
Change of Brake pad
Remark: In case there is a continuous screaming from the front
wheel when braking the vehicle during driving, check the
alarm pad for friction limit for brake pad. If there is friction
trace on the alarm pad with the brake disc, change the brake pad
1. Disassemble the front wheel;
2. Check the thickness of friction material of brake pad.
Check the thickness of friction material of brake pad, if it fails
to be within the specified range, change the brake pad.
Min thickness
2.0mm SFBraking System
Front Brake(SF)

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-25
3. Encase the piston in the caliper body.
4. Encase the piston dust cover, dust cover steel-
gripping hoop in the caliper body.
Mount of Brake Calipers
1. Mount the brake caliper and screw up the two
mounting bolts.
Fastening torque
123N
m
2. Mount the brake pads;
3. Connecting the brake pipeline;
Use the open spanner to connect the pipeline.
Fastening torque
(21
1)N
m
4. Observe the height of brake liquid level and, if
necessary, add in the brake liquid and exhaust the air
in braking system.
Notice: avoid the brake liquid of spraying on the brake disc
when exhausting the air.
5. Check to see whether there is leakage of brake liquid. 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-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-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-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-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

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