Chapter 16 The Braking System

16-1 General Information ………………………………………………………

16-2 The Disc Brake (the front brake)…….. ……………………………………
16-3 The Drum Brake (the rear brake)…….. ……………………………………
16-4 The Master Brake Cylinder and the Vacuum Booster …………. ………
16-5 Brake Pipes and Brake Hoses………………………………………………
16-6 Service and Maintenance……………………………………………………
16-7 Recommended Tightening Torque…………………………………………

ATTENTION：The fasteners stated below are important connecting parts. They

affect the functions of the important parts and system, and may result in heavy burden
of repairing cost. Therefore, if these fasteners are to be replaced, the same type or
appropriate fasteners should be used instead of poor quality or substitute fasteners.
When assembling, make sure that all components are fastened properly to the specified
tightening torque. Welding is prohibited since it will damage and weaken the metal to a
great extent.

16-1 General Information

When depress the brake pedal, the force you applied to the pedal will be enlarged through
the levers and then get to the control rod to compress the return spring. The air valve seat will
move forward, too. This movement will be passed through the reaction plate and the pushing
rod of the main cylinder, where hydraulic power is generated, to drive the slave brake
cylinder.
The master brake cylinder composed of two cylinders which are longitudinally arranged
in parallel. The 4 brake pipes connecting with the master brake cylinder form two independent
circuits. One connects with the front-right and the rear-left brakes; the other connects with the
front-left and rear-right brakes.
The proportioning valve (P valve) is equipped in the circuits for the master brake cylinder
and the rear wheels. In this braking system, the front brake is disc brake; the rear brake is
drum brake (single shoe).
The parking brake is of mechanical type. It applies braking force on the rear wheels by the
cable and the mechanical device. The parking brake and the pedal brake use one brake shoe
together.
 R
R

Front Rear

L
L
1. The master brake cylinder with vacuum booster 2. The proportioning valve
3. The parking brake lever 4. The disc brake 5. The drum brake

The master brake cylinder and vacuum booster

The front(right) + Rear(left) The front(left) +Rear(right)

A：The first piston (used for the front-left and the rear-right brake)
 B：The second piston (used for the front-right and the rear-left brake)

The master brake cylinder

Brief introduction
Longitudinal-parallel double-cylinder master brake cylinder is similar to the common
master brake cylinder. The major difference between them is that the double-cylinder brake
has two pistons that generate liquid pressure in two chambers. The pressure produced by one
chamber acts on the front-left and the rear-right brake; the liquid pressure of the other
chamber acts on the front-left and the rear-right brake.
Data about the master brake cylinder and the vacuum booster are as follows.

Bore 19.05(3/4″)
The first reservoir mm 13.5
The master brake Stroke
The second reservoir 13.55
cylinder
The first reservoir 3.85
Minimum displacement ml
The second reservoir 3.50
Dimension mm 153(6″)
The vacuum booster Servo ratio 3.1
Stroke mm 32

The vacuum check valve of vacuum booster is installed in the vacuum hose. There is an
arrow mark on the outside of the hose. Please pay attention when assembling that the hose
end with arrow should point the inlet manifold.
The vacuum booster is a kind of device with step output. It can take advantage of the
deformation of its reactive rubber to reduce the initial braking power.

The caliper assembly of the disc brake

The brake caliper has a single chamber 51.5mm cylinder. The caliper is fixed to the brake
caliper bracket by two bolts. The liquid pressure produced by depressing the braking pedal is
transformed into friction force through the brake caliper. The liquid pressure acts on the piston
and the bottom of brake cylinder hole evenly, and drives the piston to move outwards and the
brake caliper move inwards. In this way, the brake disc is clamped. The clamping depress the
friction plate against the brake disc, the friction hence produced stops the vehicle.
Details can be found in “Working principle”.

ATTENTION：Lubricate the components according to the introduction. Grease

containing air in the workshop is not allowed to enter into the brake system so to avoid
damaging the rubber. Anytime you remove some components or disassemble the pipeline,
please discharge air in the braking system. The friction plate must be replaced by whole
set. The specified torque is only for those fasteners which are dry and non-lubricated.
 1. The brake caliper pin bolt 2. The brake caliper pin
3. The dust boot 4. The friction plate (the brake pad)
5. The vent plug cap 6. The vent plug
7. The brake caliper (the disc slave brake cylinder)
8. The piston seal 9. The piston
10. The dust boot of slave brake cylinder 11. The brake disc

The working principle of brake caliper

The single-piston floating brake caliper brake
This vehicle adopts single-piston floating brake caliper brake. This kind of brake has a
slave cylinder and a piston (the slave cylinder is integrated with the brake caliper). The
hydraulic pressure produced by the slave cylinder drives the friction plate (1) by the piston
side to depress against the brake disc tightly. Meanwhile, the slave cylinder pressure makes
the floating brake caliper to move to the right side, pulling the friction plate (2) and to press
against the brake disc so to stop the wheels. Please refer to the following picture.
 The Brake Disc

The Piston
The Slave Cylinder

The Brake Caliper Body

The disc brake is different from the drum brake in that it doesn’t need additional force to
brake. But it needs to increase the working pressure of the piston and the friction plate.
Therefore, the hole of the wheel brake cylinder should be bigger. Even though there is only a
little change to the clearance between the brake disc and the friction plate, the travel of
braking pedal will be greatly affected. So, it’s necessary to adjust the clearance to minimum
by piton seal.
The Piston Seal
(Rubber Seal)
The Piston Seal
The Slave Cylinder
The Slave Cylinder (Rubber Seal)

The Piston The Piston

The Liquid Pressure “OFF” The Liquid Pressure
(No Liquid Pressure) “ON” ( Liquid Pressure)

To adjust the clearance

The piston moves forward when oil pressure acts on piston. The rubber seal that touches
the piston closely moves together with the piston due to the immense pressure. But because a
part of the rubber seal is fixed in the slave cylinder groove, the rubber may deform towards
the inside of slave cylinder, as the illustrated above. When the braking pedal is released, the
piston discharges the pressure, and the rubber seal resumes its shape and push the piston
rearwards. When the friction plate is worn, the clearance between the brake disc and the
friction plate becomes bigger, the piston travel increases, too. It demands that the rubber seal
shape should become bigger. But because a part of the rubber seal is fixed in the slave
cylinder groove, its deformation is limited to the foresaid value. The piston moves further to
compensate the clearance distance. When moving together, the piston moves back the
distance same as the clearance, while the rubber seal resumes its shape as afore said.
Consequently, the clearance between the brake disc and the friction plate always keeps to the
adjusting clearance.

The drum brake assembly (rear wheel brake)

Brief introduction
Only for the vehicle whose the front wheel is equipped with disc brake.
Drum brake assembly has an auto brake shoe clearance adjusting system, so that the
clearance between the brake drum and brake shoe are always desirable. For details, please
consult the section of “working principle”.

ATTENTION：All components to be replaced are included in the spare part kit, so

that it’s convenient for you to repair the drum brake. Following the introduction to
lubricate the components.

WARNING：When repairing the components of wheel brake, for example, when

sanding the brake friction plate, or cleaning the wheel brake components with dry brush
or compressed air, take care not to stir up dust (please use wet cloth).
When disassembling any hydraulic component or brake line, you should discharge
air form the system. The specified torques is only for those fasteners which are dry and
non-lubricated
 Rock Arm，Park Brake

1. The brake bottom plate 2. The brake shoe

3. The brake shoe return spring (A) 4. The anchor plate
5. The brake shoe return spring (B) 6. The lever spring
7. The compressed spring of the brake shoe
8. The brake shoe compressive spring lifter
9. The wheel slave cylinder 10. The rubber plug

The working principle of the rear brake

As for common drum brake, when you depress the braking pedal, the two pistons of wheel
brake cylinder force the brake shoe disc to stretch out and stop the brake drum turning.
The more serious the brake shoe been worn, the bigger the piton travel will be leading to
the increment of the braking pedal (the distance between the pedal and car body) travel.
Therefore, adjust the clearance of brake shoes by the brake shoe adjusting screw is of
necessity. Drum brake are to be adjusted regularly.
This vehicle’s rear brake is equipped with auto-adjusting system. It can adjust the
clearance (the distance between the pedal and the car body) between the brake shoe and the
brake drum automatically resulted from the damaged brake shoe.
 The clearance adjustment
All rear wheel slave cylinder are equipped with piston, piston cup and piston spring (1).
When depressing the braking pedal, then the liquid pressure may acts on the inside of piston
chamber (2)、(3).
The piston (2) moves to the left side because of this pressure (while piston (3) moves to
the right side ), as shown by the following picture, and the brake shoe are pressed against the
brake drum, thus the brake force is produced.

The Brake Shoe The Brake Shoe

The Wheel Slave Cylinder

At this moment, the travel of the brake shoe is“B”, that is the travel that “A” (the long
hole end of brake shoe ) moves to touch the lever(1) inserted in the long hole.

The Brake Shoe Plate

The Lever ⑴
The Wheel Slave Cylinder The Brake Shoe

When depressing the brake pedal, the travel of the piston and the brake shoe moving
towards brake drum is the above stated distance “B”, while “A” of the brake shoe plate
touches the lever ⑴. When the brake shoe is worn and the brake shoe clearance becomes

bigger, the force that exerted onto the lever ⑴ when they touch against each other become
bigger too. When the force exceeds 10~12kg, the “A” of the brake shoe disc makes the lever
⑴ to move the along the direction of the arrows in the picture for a distance that equals the
brake shoe friction plate wear. Thus the brake shoe is pressed against the brake drum to
produce friction.
The travel of lever ⑴ equals to the wear. The sector click pulley ⑵ that is integrated

with the lever ⑴ moves, too. Since the lever ⑴ and the click pulley ⑵ must move until
the clearances between the brake shoe and the brake drum are big enough, the position of
these two components are always in the change.
When releasing the braking pedal, the return spring makes the brake shoe to go back a
distance equal to the clearance “B”. Thus, every time you depress the braking pedal, the
clearance between the brake shoe and the brake drum adjusts to the specified value
automatically.
According to the diameter of the brake drum measured at A-A′, the clearance “B” between
the brake shoe and the brake drum should be 0.33~0.64mm. On the basis of the brake drum
diameter (A-A′), the adjusting allowance for one tooth click pulley is 0.17mm.
The spring equipped in the wheel slave cylinder can prevent the returning allowance of
piston from being bigger than the specified clearance between the brake shoe and the brake
drum.

16-2 The Disc Brake (Front)

To disassemble
The friction plate (or the brake disc)
⑴ Loosen but don’t remove the front wheel nut. Jack up the vehicle.

⑵ Support the vehicle with safety stands, disassemble the hub nut and the front wheel.
 ⑶ Remove the brake caliper bolts (2 pieces).

⑷ Remove the brake caliper.

ATTENTION：Be careful, don’t damage the brake hose, neither depress the braking
pedal when disassembling.

⑸ Disassemble the friction plate (or brake disc).

 To disassemble the piston and the piston seal
After removing the wheel, disassemble the piston and the piston seal following program.
⑴ Clean the brake caliper.

⑵ Disassemble the brake hose from the brake caliper body (the slave cylinder).

⑶ Remove the brake caliper pin bolts (2 pieces).

⑷ Blow compressed air to the slave cylinder through the bolt hole for assembling the
hoses. And push the piston out of the slave cylinder by the air pressure.

WARNING：Don’t use compressed air of too much high pressure since it may make
the piston sprung out from the slave cylinder. Please use compressed air of moderate
pressure to push the piston out slowly. When doing that, it is not allowed to place the
fingers in front of the piston.
 The Soft Cloth

⑸ Disassemble the piston seal with a thin shim similar to the thickness gauge.

CAUTION：Be careful; don’t damage the surface of the slave cylinder hole.

To disassemble the brake dis

As to disassembling steps, please see “To disassemble the hub” in chapter 14.
As to assembling steps, please see “To assembling the hub” in chapter 14.

To inspect the components

The friction plate (or the brake disc)
Inspect if the friction disc of the friction plate is worn-off. If the wear allowance exceeds
limit, please replace it. When to replace the friction plate depends on the grooves line on each
friction disc. When the groove disappears, it is time to replace it with spares.
 CAUTION：Polishing the friction plate friction disc with sand paper is absolutely
forbidden. If you polish the friction disc with sand paper, the hard sand particle from
the sand paper may inlay the friction disc, and get the brake disc damaged. The new
parts should be used.

The thickness of the friction plate (the Standard Limit

friction disc +the friction plate pad flange) 15.5mm 6.5mm

ATTENTION：When disassembling the friction plate, inspect the brake caliper

visually for brake fluid leakage. Please repair and eliminate leakage.

The slip bush of the slave cylinder

Inspect the slip bush to see if can move quickly, refer the picture below. Please repair or
replace the slip bush in case it is defected. The rubber lubricating grease should be applied to
the outer face of the slip bush. The rubber lubricating grease should be of the type of little
viscosity alternation in temperature of -40oC.

The dust boot for the slip bush and the dust boot for the slave cylinder
 Inspect the dust boots for any damage and crack. Replace when necessary.

The piston seal

The excessive or uneven wear on the friction disc indicates that the piston cannot return
freely. In such case, please replace the rubber seal.

The brake disc

Inspect the worn section of the brake disc surface for any scratch. Scratches found during
regular inspection or replacing is acceptable. If the scratch is not serious, the disc is “Ok”. If

there is deep scratch on the brake disc or the whole surface is full of scratches，please replace
the brake disc. If the disc is only scratched on one side, you can polish and repair this side.

Standard Limit
The thickness of brake disc
10mm 8.5mm
 In order to inspect the flatness of brake disc, please turn the brake disc, find out the center
point with a micrometer dial and measure at two points on the circumference.

The limit for the brake disc flatness 0.15mm

ATTENTION：Before measuring, please inspect the front wheel bearing for any
looseness.

Notes for assembling

Assemble the front brake in the opposite order of disassembling, and pay attention to the
following points:

CAUTION：

·Before assembling, please wash all components with the brake fluid that is same as
the fluid in the master cylinder.
·Never use other fluid or diluent.

·Before assembling the piston and the piston seal into the slave cylinder, please wet
them with brake fluid.
·After assembling the brake pipeline, sure to discharge air.

The piston seal

The piston seal is used for sealing the piston or the slave cylinder in addition to adjust the
clearance between the friction plate and the brake disc. Every time you do the repairing,
please use new components. When assembling the piston seal into the slave cylinder groove,
be careful not to twist the piston seal.

The piston and the dust boot

 Please assemble the dust boot onto the piston before you assemble the piston into the
slave cylinder.
After assembling the dust boot onto the slave cylinder, the outer end of the piston should
protrude out of the slave cylinder end for about 10mm as illustrated by the picture below. It’s
helpful for assembling.
Assemble the dust boot fixing ring.

The brake caliper

Before assembling the brake caliper onto the bracket, please inspect if the brake calipers
(2 pieces) is wet with grease. Check if the brake caliper pin inserted in the bracket hole can
move quickly on the thrusting direction.

ATTENTION：When the temperature is as cold as –30oC, rubber lubricating grease

whose viscosity varies little in –40oC should be used.
 The Brake Caliper Pin

Tightening Torque

Fastener N•m

1、The brake disc bolt 40~60

2、The propeller shaft castle nut 150~270

3、The hose bolt 20~25

4、The brake caliper bolt 75~90

5、The brake caliper pin bolt 22~32

 Note: Secure the split pin as shown by the picture.

The front brake hose

·Connect one end of the hose to the support bracket. Please note that when front wheel
driving straight forward the hose cannot be twisted.

Attention：After finishing assembling, please fill the fluid reservoir with brake fluid
and discharge air from the braking system. Perform trial brake. Inspect all components
assembled for leakages.

Inspection to be made after assembling the front brake

Assemble the tire. Check if it can rotate quickly by a force of 3.5 kilometers.

Attention：When performing the above stated inspecting, do notice the following

points:
⑴ Jack up the vehicle and have the front wheel (left and right) be off from the
ground.
 ⑵ The following picture shows the outer circumference of the tire.

⑶ Don’t depress the braking pedal when inspecting the tire rotation.

Please inspect the following items if the tire cannot move quickly.
·Check if the wheel bearing is damaged.

·Check the brake disc flatness (If the flatness cannot meet the requirement, the brake disc
may touch against the friction disc in the course of moving, which is the reason for stagnant
rotation.
So, please measure the flatness of the brake disc.

The Spring Force Meter The Rope

16-3 The drum brake (Rear)

To disassemble
The Brake Drum
⑴ Loosen the hub nut. Jack up the rear axle and support it with safety stands.

⑵ Remove the wheel

⑶ Disassemble the split pin, the castle nut and the washer.
 1. The split pin 2. The castle nut 3. The washer

⑷ Inspect if the parking brake lever is pulled up.

⑸ Disassemble the plug that is assembled on the back side of brake bottom plate to
enlarge the clearance between the brake shoe and the brake drum.
Insert the flat screwdriver till its top end goes into the clearance between the bracing plate
① and the adjusting lever ② as shown by the picture. Turn the flat screwdriver slightly

clockwise so to actuate the brake shoe adjusting lever ②. This will enlarge the clearance
between the brake shoe and the brake drum.

⑹ Pull out the brake drum with a special tool .

The Sliding Hammer

The Brake Drum Remover

The Brake Drum
 ⑺ Move the brake shoe compressive spring lifter, and remove the brake shoe
compressive spring, as shown by the picture.

1. The brake shoe compressive pin

2. The brake shoe compressive spring

⑻ Disassemble the parking brake cable from the parking brake shoe lever, and remove
the brake shoe.

1. The parking brake shoe lever

2. The parking brake bow cable

⑼ Suck out the brake fluid with a tool somewhat similar to the suction pipe, disassemble
the brake line horn nut from the wheel slave cylinder

⑽ Disassemble the slave cylinder bolt from the wheel, and assemble the drainage plug
that is for the wheel slave cylinder to the brake pipe to prevent the brake fluid from flowing
out.

1—The Vent Plug Cap

⑾ Remove the parking brake cable clamper, and disassemble the brake cable from the
brake bottom plate.

1. The brake bottom plate

2. The bottom plate bolt

⑿ Disassemble the brake bottom plate from the rear axis.

1. The brake bottom plate

2. The bottom plate bolt

To inspect the components

The brake drum
Check if the brake drum is clean. Measure the inner diameter of the brake drum. Inspect
the braking face for damages.

Standard Limit
The inner diameter of the brake drum
180mm 182mm

Every time you disassemble the brake drum, please wash it thoroughly, and inspect for
any crack, damage or deep groove.

The brake drum with cracks, scratches or deep grooves

Brake drums that have cracks must be replaced because they are not suitable for safe
operation. They are not to be repaired by welding. Slight scratches can be repaired. Serious or
extensive scratches may cause the brake shoe to wear excessively. Thus it’s likely that the
brake drum surface needs to be repaired .
When the friction disc is slightly worn-off, or the brake drum has groove, you should
polish the brake drum with fine sand paper, but don’t machine it.

ATTENTION：When disassembling the brake drum, please visually check if the

wheel slave cylinder leaks brake fluid. If yes, please repair the leaking part.

The brake shoe and the brake shoe disc

In case the worn and tear on the brake shoe exceeds limit, please replace the brake shoe.

The brake shoe Standard Limit

Thickness 6.0mm 2.6mm
 If the worn and tear on any of the brake shoe reaches or exceeds the limit, do replace all
the brake shoes simultaneously.

ATTENTION：Polishing the friction plate friction disc with sand paper is absolutely
forbidden. If you polish the friction disc with sand paper, the hard sand particle from
the sand paper may inlay the friction disc, and get the brake disc damaged. In case that
the friction disc needs to be repaired, you should replace it with a new one.

The wheel slave cylinder

When disassembling the brake drum, please inspect the wheel slave cylinder for oil
leakage. If any leakage is detected, please replace the components inside the wheel slave
cylinder.
Check if the disassembled components from the wheel slave cylinder have any damage,
crack or rust.

ATTENTION：The wheel slave cylinder components should be washed with brake

fluid.

The anchor plate

Check if the click pulley of anchor plate is damaged or worn-off.
 The spring
Inspect whether the spring is damaged or weakened. Replace it if any defect is found.

Pay attention to the following points when assembling:

⑴ Please apply water-proof sealant to the fitting surfaces between the brake bottom plate
and the rear axis. Tighten the bottom plate nut to specified torque.

1. The water-proof sealant

2. The bottom plate nut
Paint the water-proof sealant

18～28N·m

⑵ Apply water-proof sealant to the point where the bottom plate contact with the cable.
Run the brake cable through the brake bottom plate, and fix it by clamper.
 1. The parking brake cable
2. The clamper

Green Side（R）

Paint the water-proof sealant

⑶ Assemble the new pad to slave cylinder. Then remove the vent plug cap from the
braking pipe, and connect the braking pipe to the wheel slave cylinder. This will prevent the
brake fluid from leaking out.
⑷ Tighten the slave cylinder onto the brake bottom plate according to specified torque.

⑸ Tighten the horn nut (mentioned above) of the braking pipe to specified torque.

14～18N·m

⑹ Assemble the vent plug cap that was disassembled from brake pipe onto the vent plug.

⑺ Assemble the components according to the opposite steps of disassembling. Please see
the picture below.
 ATTENTION：
When assembling the brake shoe, never damage the wheel slave cylinder dust boot.

⑻ Push the brake shoe compressive spring to position it. Move the compressive spring
lifter and assemble the spring properly.

1. The brake shoe compressive pin

2. The brake shoe compressive spring

⑼ In order to simplify the measurement to be done on the two brake shoes along A—A′
direction, you can measure it according to the program stated in the 5 th step of the part “To
disassemble the brake drum”, which is included in the section of “The drum brake (rear)”.

⑽ After making sure that the inner side of the brake drum and the brake shoe are free of
dirt and oil, you can assemble the brake drum.
⑾ Install the washer and axis shaft castle nut.

⑿ Tighten the castle nut to the specified torque.

 1. The brake drum
2. The castle nut

80～120N·m

⒀ Fix the split pin as shown by the following picture..

The Split Pin

⒁ Assemble the axis cover(when assembling, beat the axis cover flange slightly with
hammer till the flange touches against the brake drum tightly). And tighten the wheel nut to
the specified torque.

ATTENTION：If the fit section of the axis cover is deformed or damaged, or the fit
loosens, please replace it with a new one.

The tightening torque of the wheel nut 55~70 N•m

ATTENTION：When disassembling the brake bottom plate or the brake pipe from
the wheel slave cylinder, you should discharge the air inside the braking system. (For
discharging, please refer the section of to discharge air from the brake)

⒂ After finishing all of those jobs, depress the braking pedal 4~5 times with a force
about 30 kilometer so to get the clearance between the brake drum and the brake shoe become
proper.
Adjusting the parking brake cable(please see the section“To inspect and adjust the park
brake).
 ⒃ Inspect the brake drum if free from resistance and if the brake function is “Ok”. Then,
land the vehicle to do the braking test.

16-4 The Master Brake Cylinder and the Vacuum Booster

To remove
⑴ Wash the outside of the fluid reservoir.

⑵ Discharge brake fluid with suction pipe or something similar.

⑶ Remove the screw on the fluid reservoir.

⑷ Remove the fluid reservoir.

⑸ Remove the four brake pipes from master brake cylinder.

ATTENTION：Don’t splash brake fluid onto the carboy paint coat.

⑹ Remove the split pin and the lifter pin of the vacuum booster lifter from the braking
pedal arm.
⑺ Remove four binding bolts and washers.

⑻ Remove the master brake cylinder and the vacuum booster.

 ①The fluid reservoir ②The screw ③The rubber sleeve

④The nut ⑤The binding nut

To disassemble
⑴ Disassemble the retainer snap ring.

⑵ Drive out the first piston with compressed air as shown by the picture. You must be
careful since the first piston may shoot out when being driving out.

①The retainer snap ring ②Compressed air

 ③The master brake cylinder

⑶ Remove the piston locking bolt. Then blow compressed air through the locking bolt
hole to press out the second piston.

①The piston locking bolt ②Compressed air

ATTENTION：Do not loosen the locking nut“A” of the lifter. If you loose it, you must
adjust and tighten this nut to the measurement range stated below. The data in the
picture don’t include the washer thickness.

To inspect the components

The components inside the master cylinder
Inspect all of the disassembled components for worn-off and damage. Replace when
necessary.

ATTENTION：

① Wash the disassembled components with brake fluid.

② The old piston cup should not be reused.

Inspect the bore of the master brake cylinder for scratches and corrosion. The corroded
cylinder had better be replaced. The indication of corroding is notch or excessive roughness.
ATTENTION：Never use abrasive material to polish the bore of the master brake
cylinder made of aluminum so to prevent damaging the cylinder bore.

Wash the master brake cylinder with clean brake fluid. Get rid of redundant cleaning
liquid from the cylinder. Don’t wipe off the liquid on the brake master cylinder with a piece of
cloth, because the fuzz of the cloth may be left over to contaminate the master cylinder bore.

The fluid reservoir

ATTENTION：Don’t use damper oil or mineral oil containing fluids. Don’t use
container that has ever been be used to hold mineral oil or is wet by water. Mineral oil
can make the rubber parts in the braking system expand or deform. If water is mixed
into the brake fluid, it will lower the boiling point of the brake fluid. All the containers
for holding the brake liquid should be capped to prevent them from being contaminated.

The fluid reservoir should be filled with Lishan 8017 synthetic brake fluid. And the fluid
should be filled to the MAX. marking line.

①The fluid reservoir cap ②The fluid reservoir

③The master brake cylinder ④The binding nut

⑤The horn nut

To assemble

ATTENTION：Before assembling, please wash all components in the recommended

brake fluid.

⑴ Assemble the second piston according to the following picture.

 ① The second piston return spring ② The return spring seat

③ The piston cup ④ The second piston

⑤ The piston pressure cup

⑵ Assemble the second piston assembly into the master brake cylinder.

⑶ Assemble the first piston into the master brake cylinder.

⑷ Press and assemble the retainer snap ring.

①The lifter ②The retainer snap ring

⑸ After assemble the piston to the proper place, you can assemble the piston locking bolt,
and tighten the bolt to the specified torque.
 ⑹ Install the assembly onto the vehicle, please see the section“Assembling”.
Pay attention to the following items when installing:
ATTENTION：Please refer the notes at the beginning of this chapter.

⑴ Assemble the master brake cylinder and the vacuum booster as shown by the picture.
Tighten the binding nut to the specified torque.
⑵ Assemble the vacuum booster lifter onto the braking pedal. Secure the split pin.

⑶ Connect the four brake pipes properly. Tighten the horn nut to the specified torque.

⑷ When you are to use new rubber sleeve, please lubricate it with brake fluid same as
that in the fluid reservoir. Then press the rubber sleeve into the master cylinder.
⑸ Assemble the fluid reservoir, and tighten the screw to specified torque.

⑹ Fill the fluid reservoir with specified brake fluid.

When the installing procedure is over, please inspect the height of the braking pedal.
Discharge air from the system and check for leakages.

16-5 The Brake Pipes and Hoses

To disassemble and assemble
⑴ Discharge the brake fluid with a suction pipe or something similar.

⑵ Clean the dirt and impurity from the accessories at both ends of the hoses or pipes.
Remove the brake pipes and hoses.
⑶ Assemble the brake pipes and hoses according to the opposite orders for
disassembling. When assembling the hoses, take care not to twist or knot them. Check if the
hoses get into contact with the suspension assembly. Inspect the utmost right and left steering
position. If the hose does touch something, please disassemble it and get it adjusted. Fill brake
fluid into the fluid reservoir and keep the level at proper height. Discharge air from the
braking system.

The tightening torque

The horn nut of the brake pipe 14~18 N•m
The bolt of the brake hose 20~25 N•m
The four-way connector bolt 8~12 N•m
The proportioning valve bolt 8~12 N•m

ATTENTION：Sure to assemble the “E” clamp into the brake hose groove.

The ‘E’Clamp

·After the assembling job is finished, you depress the braking pedal and inspect all the
connectors to see if it leaks.
 6
7
9
10

12

13
3

11
2

1
14

1. The brake hose

·Don’t twist the brake hose when assembling it or connecting it to the brake pipe.
 ·The front hose should not be twisted when the steering wheel is in the position for
straightforward.
2. ⑴ clamping position “A” ⑵ front

⑶ vehicle body ⑷ bolt ⑸ parking brake cable

3. ⑴ clamping position “B” ⑵ vehicle body ⑶ oil tank

⑷ bolt ⑸ parking brake cable

4. ⑴ clamping position “C” ⑵ vehicle body ⑶ bolt

⑷ parking brake cable

5. ⑴ clamping position “D”(looking from the arrow①) ⑵ vehicle body

⑶ parking brake cable ⑷ the outside of vehicle body

⑸bracket ⑹ rubber sleeve

6. ⑴clamping position “E”(looking from the arrow②) ⑵ vehicle body

⑶ bolt ⑷ the outside of vehicle body ⑸bracket

⑹rubber sleeve ⑺ parking brake cable ⑻ stay bar

⑼ screw

7. ⑴ rear ⑵ front

8. ⑴clamping position “G.K” ⑵ the inside of vehicle body(“G” clamping position)

⑶upward ⑷the front side(“K” clamping position)

9. ⑴clamping position “H” ⑵ the outside of vehicle body

10. The brake bottom plate(right & left)
The brake bottom plate
a. to apply sealant here
b. When you assembling the bottom plate to the flange of the rear axis, please apply
water-proof sealant to the fitting surface between the two components.
11. ⑴clamping position “J” ⑵ upward ⑶ the inside of vehicle body
 12. ⑴clamping position “I” ⑵ the inside of vehicle body

13. ⑴clamping position “L”

14. ⑴ E clamp ⑵ washer

·The second piston side

·The first piston side

·To connect the left-front hose

·Clamping position “K”

·4-way connector

·The proportioning valve

·The green mark

16-6 Service and Maintenance

To test the brake on road
The brake should be tested on dry, clean and level road. Braking gently or fiercely at
every speed to do the test, so to check if the vehicle can be stopped smoothly and effectively.
Meanwhile, check if the vehicle swings from side to side when no braking is operated. If
it swings, you should check the tire pressure, the wheel alignment and if the accessories of the
front suspension are loose. To find other reasons, please see the chapter “Trouble shooting ”.

The brake fluid leakage

Inspect the fluid level in the master brake cylinder. The level going down slightly can be
explained as that the friction disc acceptably worn. If the level is too much low, it means that
the system leaks. At this moment, you should inspect the whole braking system. Even though
there is only a minor leakage, you should eliminate this defect or replace the defected
components.

To inspect the brake fluid level

Please have brake fluid specified either on the fluid reservoir cap or in the on-board
manual.
No other brake fluid is to be used.
The brake fluid level should be between the marking lines as “MIN” and “MAX”.
If the warning lamp lights when the vehicle is working, you must replenish the brake fluid
until the level reached at the “MAX” marking line.
 If the fluid level goes down quickly, you should inspect the braking system for any
leakage. Repair the leaking part, and fill the fluid to the specified level.

To fill fluid into the fluid reservoir

ATTENTION：Don’t use damper oil or mineral oil containing fluids. Don’t use
container that has ever been be used to hold mineral oil or is wet by water. Mineral oil
can make the rubber parts in the braking system expand or deform. If water is mixed
into the brake fluid, it will lower the boiling point of the brake fluid. All the containers
for holding the brake liquid should be capped to prevent them from being contaminated.

The brake fluid to be filled into the fluid reservoir is specified by the inscribed words on
the fluid reservoir cover or is specified in the or-board manual.
The brake fluid should be filled till the level reach the “MAX” marking line.

To adjust the brake pedal’s free height

If the pedal is as high as the clutch pedal, it is “Ok”.
When the park lamp switch has been disassembled, to install it properly, please see the
following section“To adjust the park lamp switch”.

To adjust the park lamp switch

When assembling the switch, you should make adjustment according to the following
program:
Raise the brake pedal towards yourself and keep it at this position. Adjust the switch
position to make the clearance between the threaded end and the brake pedal’s contact plate
(“A” in the picture shows) be within 0.5~1.0mm. Then tighten the locking nut to the specified
torque.
 ①The brake pedal ②The contact plate

③The park lamp switch ④The locking nut

To check the pedal stroke travel

 ⑴ When the braking pedal is depressed by a force about 30 kilometers, you measure the
distance“B” that is between the pedal arm and the front body wall. The distance must be
larger than 45mm.
⑵ If the distance is smaller than 45mm, the major reason may be that the rear brake shoe
has been excessively worn-off, or there is air inside the brake system.
In case that the brake shoe was replaced and the air inside the system has been discharged,
still the distance “B” is still smaller than 45mm, the other possibility, which is rarely seen, is
that the automatic adjustment mechanism of the brake shoe failed.
·To inspect the brake shoe, please see the section“The brake shoe and brake shoe disc”.

·To discharge air from the brake system, please see“To discharge air from the brake
system”.
· Disassemble the brake drum to inspect (See the section“Drum brake”). Repair or
replace the defected parts when necessary.

To inspect the brake pipes and hoses

The hoses
The brake hoses should be inspected more than 2 times every year, because they always
pass the liquid pressure from the vehicle’s braking oil pipe to the rear slave cylinder and the
front brake caliper. Inspect the brake hoses for any damage, crack, leakage and local
protruding. Check the outer sleeve for any damage. The lamps and the mirror also should be
inspected. Please replace the brake hose if any defect has been found.

The brake pipe

Inspect the braking pipe for any damage, crack, dent and erosion. Please replace when
necessary.
 To inspect the friction plate’s friction disc
Inspect the friction disc according to the maintenance table regularly. When disassembling
the tire (or replacing the wheel for other reasons), please inspect the friction disc too.
To inspect the friction disc abrasion, please see the section of “To inspect the
components”.

To inspect the brake disc

Inspect the brake disc regularly according to the maintenance table.
Please see the section of “The brake disc”.

To inspect the rear brake shoe and the friction disc

Inspect the brake shoe and the friction disc regularly according to the maintenance table.
To inspect the brake shoe and the friction disc, see the section “The brake shoe and brake
shoe disc” of this chapter.

To inspect the rear brake drum

Inspect the brake drum regularly according to the maintenance table.
See the section in this chapter “To inspect the components”.

To inspect and adjust the parking brake

⑴ To inspect the park brake lever
Pull the parking brake lever to the proper position by a hand to brake completely. Inspect
how many click pulley teeth has been traveled by the parking brake lever. If the teeth exceed
8, please adjust the park brake cable.

ATTENTION：Inspect the teeth ends of the click pulley for any damage. Please
replace the park brake lever if there is any damage.
 Pull Up

⑵ To adjust the travel of the park brake lever

a. Hold the center of the park brake lever handle, and pull it up with a force about 20
kilometers. Inspect the level travel to see whether it meets the following specification.
b. Please adjust the park brake cable if it exceeds standard.

ATTENTION：Before adjusting the park brake cable, please ensure the following
conditions.

·The abrasion of the rear brake shoe should not exceed limit. The automatic adjusting
mechanism works well.
c. Loosen the following adjusting nut so to be adjusted to specified value.
The right and the left outer cable should be adjusted to the same length.
After adjusting, inspect the brake drum to see if it is seized.

When pulling up the park brake lever with 20

3~8 teeth
kilometers force, the travel ①of should be :

①The park brake lever ②The brake cable ③The front of nut
 ⑶ To inspect the park brake cable
Inspect the park brake cable for any damage and quick movement. Replace it when
necessary.

To inspect the clearance of the brake pedal

The clearance of the brake pedal should be within the specified range as the following
picture shows. If it’s not up to standard, please inspect if the park brake lamp switch has been
properly installed. Adjust it when necessary.
Meanwhile, please inspect whether the fasteners for assembling the pedal shaft and the
vacuum booster loosens. Replace them when necessary.

The Pedal Clearance 1~8mm

To adjust the drum brake (rear)’s shoe

Although the brake (rear) has automatic adjusting mechanism, when you replace the brake
shoe or disassemble the brake drum for some repairing, you must make some adjustment so
that the clearance between the brake drum and the brake shoe is “Ok”.
After assembling all components properly, you depress the brake pedal 3~5 times with a
force about 30 kilometers. It can adjust itself automatically.
Inspect whether the brake drum is seized. Check if the brake system could performance
correctly. After lowering the vehicle from the lifter, please do the braking test.

To wash the braking system

Any time you are to install a new part to the brake system to replace the old one, you had
better clean the brake system completely with clean brake fluid.
Meanwhile, it’s suggested that you renew the brake fluid once every two years.

To discharge air from the brake

ATTENTION：The brake fluid can damage the paint coat seriously. If it drops to the
paint coat accidentally, please wipe it off immediately and wash the paint coat.

You should perform the discharging operations every time air comes into the braking
system.
The braking pipe line of this system is arranged as diagonal combination. When
disassembling the brake pipes or hoses from wheel, the discharging operation should be done
at both ends of them. When disassembling any connector of the master cylinder and the
connectors between the master cylinder and each brake, the brake’s system of each wheel (4)
must be vented.

ATTENTION：The discharging operation should start from the wheel farthest away
from the master cylinder. Then the front brake caliper in the same brake pipe. The other
brake pipe is to be discharged in the same way.

The Left Wheel’s Slave Cylinder The Left Brake’s Caliper

Rear Front

The Right Wheel’s Slave Cylinder The Right Brake’s Caliper

⑴ Fill the master cylinder reservoir with brake fluid. When discharging, the reservoir
should have 1/2 of the fluid at least.
⑵ Disassemble the vent plug cap.
Insert a nylon pipe into the vent plug hole on the wheel’s slave cylinder, and insert the
other end of the nylon pipe into a container.
⑶ Depress the brake pedal several times. Then loosen the plug for1/3~1/2 circle while
depressing the pedal..
⑷ When the liquid pressure in the slave cylinder falls to zero, tighten the vent plug.

⑸ Operate repeatedly till no air bubble in the brake pipe.

⑹ When there is no more air bubble, you tighten the vent plug while the brake pedal
being depressed.
⑺ Then assemble the vent plug cap.

⑻ After finishing the discharge operation, you should apply hydraulic pressure to the
brake pipes to inspect for any leakage.
⑼ Fill the brake fluid till the level in the reservoir reached specified mark.

⑽ Inspect the brake pedal for ‘softness’. If you feel it soft, you must repeat the whole
operation.

16-7 The Recommended Tightening Torque

Fastener Tightening torque ( N•m)
1. The brake disc bolt 40~60
2. The brake caliper bolt 75~90
3. The brake caliper pin bolt 22~32
4. The brake bottom plate nut 18~28
5. The master cylinder nut 10~16
6. The propeller shaft castle nut 150~270
7. The four-way connection bolt 8~12
8. The proportioning valve 8~12
9. The horn nut 14~18
10. The brake pedal shaft nut 18~28
11. The park lamp switch nut 10~15
12. The brake hose bolt 20~25
13. The wheel nut 55~70
14. The wheel slave cylinder bolt 10~13
15. The rear brake drum nut 80~120
16. The vent plug 7~10