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    206-02 Rear Disc Brake PICKUP JMC.

    Uploaded by

    Rusonegro
    This document provides specifications, descriptions, diagnosis, and removal/installation instructions for the rear disc brake system on a Boomday vehicle model. It includes: 1) Specifications for materials, parameters, and torque values related to the rear disc brake components. 2) A description that the rear disc brake shares components with the parking brake and uses a rear wheel cylinder with dual pistons and brake shoes mounted on a brake carrier with the disc mounted on the half axle. 3) Instructions to refer to the general brake system information for diagnosis and testing of the rear disc brake. 4) Illustrations and part numbers for the disc brake assembly components and instructions for removing and installing the brake disc,

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    206-02 Rear Disc Brake PICKUP JMC.

    Uploaded by

    Rusonegro
    66 views10 pages
    This document provides specifications, descriptions, diagnosis, and removal/installation instructions for the rear disc brake system on a Boomday vehicle model. It includes: 1) Specifications for materials, parameters, and torque values related to the rear disc brake components. 2) A description that the rear disc brake shares components with the parking brake and uses a rear wheel cylinder with dual pistons and brake shoes mounted on a brake carrier with the disc mounted on the half axle. 3) Instructions to refer to the general brake system information for diagnosis and testing of the rear disc brake. 4) Illustrations and part numbers for the disc brake assembly components and instructions for removing and installing the brake disc,

    Original Description:

    JMC

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    © © All Rights Reserved

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    This document provides specifications, descriptions, diagnosis, and removal/installation instructions for the rear disc brake system on a Boomday vehicle model. It includes: 1) Specifications for materials, parameters, and torque values related to the rear disc brake components. 2) A description that the rear disc brake shares components with the parking brake and uses a rear wheel cylinder with dual pistons and brake shoes mounted on a brake carrier with the disc mounted on the half axle. 3) Instructions to refer to the general brake system information for diagnosis and testing of the rear disc brake. 4) Illustrations and part numbers for the disc brake assembly components and instructions for removing and installing the brake disc,

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    66 views10 pages

    206-02 Rear Disc Brake PICKUP JMC.

    Uploaded by

    Rusonegro
    This document provides specifications, descriptions, diagnosis, and removal/installation instructions for the rear disc brake system on a Boomday vehicle model. It includes: 1) Specifications for materials, parameters, and torque values related to the rear disc brake components. 2) A description that the rear disc brake shares components with the parking brake and uses a rear wheel cylinder with dual pistons and brake shoes mounted on a brake carrier with the disc mounted on the half axle. 3) Instructions to refer to the general brake system information for diagnosis and testing of the rear disc brake. 4) Illustrations and part numbers for the disc brake assembly components and instructions for removing and installing the brake disc,

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 10

    206-02-1 Rear Disc Brake 206-02-1

    Section 206-02 Rear Disc Brake


    Applicable Model: Boomday

    CONTENTS PAGE
    Specifications
    Specifications ................................................................................................................................ 206-02-2
    Descriptions and Operations
    Rear Disc Brake ............................................................................................................................ 206-02-3
    Diagnosis and Testing
    Rear Disc Brake ............................................................................................................................ 206-02-4
    Removal and Installation

    Disc Brake - Parts Illustration ................................................................................................... 206-02-5


    Brake Disc.................................................................................................................................... 206-02-6
    Brake Shoe .................................................................................................................................. 206-02-7
    Brake Wheel Cylinder................................................................................................................. 206-02-9
    Brake Carrier ............................................................................................................................. 206-02-10

    2009.06 Boomday
    206-02-2 Rear Disc Brake 206-02-2
    Specifications

    Material Specifications

    Item Specification
    SAEJ 1703 or FMVSS
    D0T 3 Brake fluid
    11
    Lubricant grease -

    Parameter Specification

    Item Specification
    Gap between brake disc and brake lining at the both ends of
    0.25~0.40
    brake shoe
    Brake shoe
    Limiting wearout thickness of brake shoe 1.0 mm
    Max. thickness difference between brake shoes 1.0 mm
    Brake disc
    Standard inside diameter of brake disc 254 mm
    Max. inside diameter for brake disc machining
    Limiting wearout inside diameter of brake disc 255.5 mm
    Max. radius run-out of brake disc (installation) 0.15 mm

    Torque Specification

    Item Specification
    Collar nut for brake hose 16 ± 3
    Wheel cylinder retaining bolt 10 ± 2
    Wheel speed sensor retaining bolt 8

    2009.06 Boomday
    206-02-3 Rear Disc Brake 206-02-3
    Descriptions and Operations

    Rear Disc Brake


    Rear disc brake features the following:
    ● Share the same brake set with parking device.
    ● Rear wheel cylinder with dual pistons.
    ● The brake shoe is mounted on brake carrier.
    ● The brake disc is mounted on half axle.

    2009.06 Boomday
    206-02-4 Rear Disc Brake 206-02-4
    Diagnosis and Testing

    Rear Disc Brake

    Refer to section 206-00 Brake System – General


    Information.

    2009.06 Boomday
    206-02-5 Rear Disc Brake 206-02-5
    Diagnosis and Testing

    Disc Brake – Parts Illustration

      

     

     

     
    

    

    Item Description Item Description


    1 Brake disc 8 Brake wheel cylinder
    Pressure spring and spring seat for 9 Brake carrier
    2
    brake shoe
    10 Wheel cylinder mounting bolt (2 pcs)
    3 Upper release spring
    11 Pin shaft
    4 Bottom release spring
    12 Adjuster lever spring
    5 Brake shoe
    13 Parking brake control lever
    6 Adjusting retainer
    7 Brake shoe adjuster

    2009.06 Boomday
    206-02-6 Rear Disc Brake 206-02-6
    Removal and Installation

    Brake Disc
    Materials

    Item Specification
    D0T 3 Brake fluid SAEJ 1703 or FMVSS
    116

    Removal and Installation

    WARNING: The unapproved brake fluids


    other than D0T 3 will cause brake to work
    improperly.
    Failure to follow the above instruction
    may result in personal injury.
    CAUTION: Keep lubricant grease, oil,
    brake fluid or other dirts from the friction
    surface of brake disc. No stained brake
    disc can be installed.
    1. Release parking brake.
    2. Remove wheels and tires. Refer to section
    204-04 for more information.
    3. Remove brake disc.
    1 Remove set screws.
    2 Take down brake disc.

    4. Check whether brake disc wearout goes


    beyond limit, and replace it when necessary.
    Refer to section 206-00 for more information.
    5. The installation sequences are contrary to
    the dismantling sequences.
    6. Check brake fluid and fill when necessary.
    7. Test working conditions of the brake.

    2009.06 Boomday
    206-02-7 Rear Disc Brake 206-02-7
    Removal and Installation

    Brake Shoe 2 Remove parking brake cable, remove rear


    brake shoe and control lever components.
    Materials

    Item Specification

    Lubricant grease -
    SAEJ 1703 or FMVSS
    D0T 3 Brake fluid
    116

    Removal and Installation


    WARNING: The unapproved brake fluids
    other than D0T 3 will cause brake to work
    improperly. Failure to follow the above
    instruction may result in personal injury. 3 Remove control lever.
    No stained brake shoe can be installed.
    CAUTION: Keep lubricant grease, oil,
    brake fluid or other dirts from the friction 
    material of brake shoe.
    ATTENTION: The following diagram
    shows how to dismantle the right brake 
    shoe, which is similar to the left brake 
    shoe.
    1. Remove wheels and tires. Refer to section
    204-04 for more information
    2. Remove brake disc. See this Section for
    more information.
    3. Remove pressure spring and spring seat
    for brake shoe. Item Specification
    4. Remove brake shoe.
    CAUTION: Do not damage dust cover for 1 Snap spring
    brake wheel cylinder, and fix the wheel
    cylinder plunger with rubber band. 2 Pin shaft
    1 Remove release spring, and take down
    front brake shoe. 3 Control lever

    5. C h e c k w h e t h e r b r a k e s h o e w e a r o u t
    goes beyond limit, and replace it when
    necessary. Refer to section 206-00 for more
    information.

    2009.06 Boomday
    206-02-8 Rear Disc Brake 206-02-8
    Removal and Installation

    6. For installation, reverse the removal


    procedures.
    ● Spread lubricant grease on the sliding
    surface above brake carrier during
    installation.

    7. Check brake fluid and fill when necessary.


    8. Test working conditions of the brake.

    2009.06 Boomday
    206-02-9 Rear Disc Brake 206-02-9
    Removal and Installation

    Brake Wheel Cylinder ● Tighten up to 10 ± 2 Nm during installation.


    Materials

    Item Specification

    SAEJ 1703 or FMVSS


    D0T 3 Brake fluid
    116

    Removal and Installation


    WARNING: The unapproved brake fluids
    other than D0T 3 will cause brake to work
    improperly. Failure to follow the above
    instruction may result in personal injury.

    CAUTION: Do not splash brake fluid onto 5. Check whether there is leakage in wheel
    the paint surface. If so, please clean it cylinder and replace it when necessary.
    with water immediately 6. For installation, reverse the removal
    1. Remove wheels and tires. Refer to 204-04 procedures.
    for more information.
    7. Fill and vent air for brake system. Refer to
    2. Remove brake shoe. Refer to this Section section 206-00 for more information.
    for more information.
    3. Remove brake hose from wheel cylinder.

    CAUTION: Seal brake hose to prevent


    against brake fluid Leakage or dirt.
    ● Tighten up to 16 ± 3 Nm during installation.

    4. Remove 2 bolts and take down wheel


    cylinder.

    2009.06 Boomday
    206-02-10 Rear Disc Brake 206-02-10
    Removal and Installation

    Brake Carrier
    Removal and Installation
    1. Remove wheels and tires. Refer to section
    204-04 for more information.
    2. Remove brake wheel cylinder. Refer to this
    Section for more information.
    3. Remove parking brake cable from brake
    carrier.
    1 Release clamp.
    2 Remove the cable.

    4. Dismantle wheel speed sensor if there are


    tools equipped.
    1 Remove 1 bolt.
    ● Tighten up to 8 Nm during installation.
    2 Remove wheel speed sensor.

    5. Remove half axle. Refer to section 205-05


    for more information.
    6. Remove brake carrier.
    7. For installation, reverse the removal procedures.

    2009.06 Boomday

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