Front Drum Brake

Contents
Front Brake ....................................................................................................................................................... 3
I. Structure of Front Brake Assembly ........................................................................................ 3
II. Brake Clearance Adjustment .................................................................................................... 4
III. Replacement of Front Adjuster Assembly ............................................................................ 7
IV. Replacement of Front Brake Air Chamber Assembly ...................................................... 10
V. Replacement of Front Brake Cam ......................................................................................... 12
VI. Replacement of Front Brake Friction plate ......................................................................... 15
VII. Replacement of Front Brake Bottom Plate ......................................................................... 19

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Front Drum Brake

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 Front Drum Brake

Front Brake
I. Structure of Front Brake Assembly

1. Elastic retainer ring 11. Bolt 21. Locating bolt 31. Roller
2. Brake adjuster 12. Air chamber bracket 22. Locking wire 32. Elastic retainer ring
3. Cotter pin 13. Camshaft spacer 23. Supporting pin 33. Return spring pin
4. Flat washer pin 14. Gasket 24. Rivet 34. Dust cover
5. U-fork 15. Front brake air 25. Brake gasket 35. Grease nozzle
6. Flat head pin chamber 26. Brake shoe 36. Gasket
7. Locking nut 16. Bolt 27. Return spring 37. Oil seal
8. Bolt 17. Spring washer 28. Spring washer 38. Camshaft
9. Spring washer 18. Rubber plug 29. Screw 39. Brake friction plate
10. Spring washer 19. Dust cover 30. Roller pin
20. Brake bottom plate

Structure of Front Brake Assembly 3

Front Drum Brake

II. Brake Clearance Adjustment

(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Double offset ring open-end spanner S17, slotted

Common tools
screwdriver

Special tools —

Inspection tools Feeler gauge

Auxiliary materials —

(II) Operation steps

Adjustment

1. Fix the wheels.

1). Park the vehicle on a level road, pull up
the manual valve handle and block the
front and rear sides of four wheels with
triangular wood filler blocks.

2. Eliminate the brake clearance.

1). Clockwise rotate the adjuster worm
shaft to its limit position.
Warning: 1. Never change the stroke of
the pushrod with the method used for
twisting the pushrod connecting fork of
brake air chamber.
2. Make sure the air pressure in air
reservoir is above 700 kPa when the rear
brake is adjusted.
3. The rear brake clearance can be
adjusted only when the parking brake is
released.

4 Brake Clearance Adjustment

 Front Drum Brake

3. Adjust the brake clearance.

1). Remove 1 plug cap of rear dust cover.

2). Rotate the adjuster worm shaft

anticlockwise and simultaneously
measure the clearance between the
brake drum and brake shoe friction
plate with a feeler gauge.
Standard dimension: 0.3~0.5 mm

Brake Clearance Adjustment

Adjustment of Clearance Between Axles with Manual Adjuster

Now set the double offset ring spanner onto the

worm head and rotate the worm shaft to allow
the friction surface of brake shoe to contact with
that of brake drum, and then counter-rotate the
adjuster worm shaft for 1/3~1/2 turn. The
clearance in the middle of brake friction plate
shall be about 0.3~0.5 mm and the brake drum
shall be able to rotate freely without colliding with
other parts.

Brake Clearance Adjustment 5

Front Drum Brake

Adjustment of Clearance Between Axles with Automatic Adjuster

Just take the automatic adjuster with control arm

for example, for those with other structures, refer
to the instructions from adjuster manufacturers.
1). Notice on installation: Make sure the
direction of the arrow on the adjuster shell is
consistent with the pushing direction of
pushrod. The control arm assembly must be
pushed into position.
2). Don’t use pneumatic or electric tools when
rotating the worm head. The worm head
shall rattle when measuring the opposing
adjustment torque (the direction in which the
clearance increase) of worm head with a
torque wrench, and the measured torque
shall not be less than 18 N·m, or the
adjuster shall be replaced.

There is no need to adjust the brake clearance in

normal. However, if dragging friction occurs
between the brake drum and brake shoe, set the
double offset ring spanner onto the worm head
and rotate the worm shaft to allow the friction
surface of brake shoe to contact with that of the
brake drum. Then counter-rotate the adjuster
worm shaft for 1/2~3/4 turn, during this period it
shall rattle and the brake drum shall be able to
rotate freely without colliding with other parts.
After that, apply brake for 40 times with air
pressure not less than 700 kPa in the site, and
the clearance shall be 0.6~1.0 mm.
Notice: Operations with “×” icons are
incorrect.

6 Brake Clearance Adjustment

 Front Drum Brake

III. Replacement of Front Adjuster Assembly

(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Double offset ring open-end spanner S17, slotted

Common tools
screwdriver, slip joint pliers

Special tools —

Inspection tool Feeler gauge

Auxiliary materials Lithium base grease

(II) Operation steps

Removal
1. Fix the wheels.
2. Tilt the cab.
3. Remove the front adjuster assembly.

1). Remove the cotter pin, flat head pin,

spring washer and plain washer.

2). Remove the spring snap ring.

Replacement of Front Adjuster Assembly 7

Front Drum Brake

3). Remove the adjuster.

Check
1. Check the front adjuster.
1). Check the wear conditions of the inner
chamber spline of front adjuster;
2). The lithium base grease can be
injected into the grease nozzle
smoothly;
3). Turn the worm shaft, and it shall be
able to be turned freely clockwise and
anticlockwise.
Notice: Replace the front adjuster
assembly if the worm shaft fails to be
rotated freely.

Installation
1. Install the front adjuster assembly.
1). Make sure the pushrod of front brake
air chamber is in initial position before it
is installed;
2). Move the front brake camshaft;
3). Insert the front adjuster and 1 adjusting
shim into the camshaft;
Notice: Check whether the installation
angle of the adjuster meets the
requirements for β (the initial installation
angle β shall be 100°~105°), otherwise
readjust it;
4). Rotate the worm shaft clockwise to
reduce the brake clearance;

8 Replacement of Front Adjuster Assembly

 Front Drum Brake

5). Install one set of adjusting shims and a

large cotter pin;
Notice: 1. Add more adjusting shims as
appropriate in order to make sure the
center of adjuster handle is consistent
with that of the chamber pushrod.
2. Make sure there is an axial clearance
of 0.5~1 mm between the adjuster and
camshaft.

6). Install 1 adjusting plain washer, 1 small

cotter pin and 1 pin shaft and connect
the front adjuster and front brake air
chamber;
7). Inject lithium base grease via grease
nozzle.
2. Adjust the brake clearance.
Refer to Brake Clearance Adjustment.
3. Lower the cab.

Check on Vehicle
1. Start the engine.
Inflate the air reservoir to make sure the air pressure is above 700 kPa.
2. Check the braking performance.
Check the braking process for any seizing, abnormal noise, etc.

Replacement of Front Adjuster Assembly 9

Front Drum Brake

IV. Replacement of Front Brake Air Chamber

Assembly
(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Sleeve S17/S18, double offset ring open-end

Common tools spanner S19/S22, slotted screwdriver, slip joint
pliers

Special tools —

Inspection tool Torque wrench (0~200 N·m), feeler gauge

Auxiliary materials Thread sealant

(II) Operation steps

Removal

1. Fix the wheels.

2. Tilt the cab.
3. Remove the nylon pipe and pipe joint of
front brake air chamber.
1). Unscrew the nylon pipe nut;
2). Disconnect 1 nylon pipe;
3). Remove 1 pipe joint.

4. Remove the front brake air chamber

assembly.
1). Remove 1 cotter pin, 1 plain washer
and 1 pin shaft between the front brake
air chamber and front adjuster;
2). Remove 2 bolts between the front
brake air chamber and chamber
bracket;
3). Take off the front brake air chamber
assembly.

10 Replacement of Front Brake Air Chamber Assembly

 Front Drum Brake

Installation
1. Install the front brake air chamber
assembly.
1). Install the front brake air chamber
assembly on its bracket with 2 bolts;
Tightening torque: 39~59 N·m
2). Connect and fix the front brake air
chamber and front adjuster with 1 pin
shaft, 1 plain washer and 1 cotter pin.

2. Install the pipe joint and nylon pipe of

front brake air chamber.
1). Install the pipe joint on the front brake
air chamber;
Notice: Wash the thread of pipe joint with
washing agent.
2). Coat a circle of thread from root with
thread sealant, with the coat width no
less than three courses of thread;
3). Install the pipe joint on the front brake
air chamber and make sure the
mounting position is correct;
4). Connect the nylon pipe and tighten the
nut.
3. Adjust the brake clearance.
Refer to Brake Clearance Adjustment.
4. Lower the cab.

Check on Vehicle
1. Start the engine.
Inflate the air reservoir to make sure the air pressure is above 700 kPa.
2. Check the braking performance.
Unscrew the air pipe at the inlet of front brake air chamber, at which there shall be air
pressure input when the brake pedal is stepped down and no input when the brake pedal is
released.

Replacement of Front Brake Air Chamber Assembly 11

Front Drum Brake

V. Replacement of Front Brake Cam

(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Common tools Sleeve S13/S17/S41, slotted screwdriver, jack

Special tool for return spring, special tool for nut

Special tools
adjustment

Inspection tool Torque wrench (0~750 N·m), feeler gauge

Auxiliary materials Lithium base grease

(II) Operation steps

Removal
1. Fix the wheels.
2. Tilt the cab.
3. Jack the front axle.
4. Remove the front brake drum assembly.
Refer to Replacement of Front Brake Drum.
5. Remove the front adjuster assembly.
Refer to Replacement of Front Adjuster
Assembly.
6. Remove the front brake cam.
1). Remove the return spring with the
special tool for the return spring of
brake shoe;
Notice: Tie the brake shoe with a ring or
iron wire before removing the return
spring.

2). Remove the cam oil seal and brake

cam.

12 Replacement of Front Brake Cam

 Front Drum Brake

Check
1. Check the front brake cam.
1). Check the wear conditions of cam
spline;
2). Check the cam for deformation and the
surface for scratch.
Notice: Replace the cam if the cam spline
or its surface is worn seriously.

Installation
1. Install the front brake cam.
1). Apply lithium base grease on the
contact surface between the front brake
cam and bushing;

2). Insert the cam into the front cam seat

bushing;

3). Install the return spring with the special

tool for the return spring of brake shoe.
Notice: Tie the brake shoe with a ring or
iron wire before installing the return
spring.

Replacement of Front Brake Cam 13

Front Drum Brake

2. Install the front adjuster assembly.

Refer to Replacement of Front Adjuster Assembly.
3. Install the front brake drum.
Refer to Replacement of Front Brake Drum.
4. Lower the front axle.
5. Adjust the brake clearance.
Refer to Brake Clearance Adjustment.
Standard dimension: 0.3~0.5 mm
6. Lower the cab.

Check on Vehicle
1. Start the engine.
Inflate the air reservoir to make sure the air pressure is above 700 kPa.
2. Check the braking performance.
Check the braking process for any seizing, abnormal noise, etc.

14 Replacement of Front Brake Cam

 Front Drum Brake

VI. Replacement of Front Brake Friction Plate

(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Sleeve S13/S41, double offset ring open-end

Common tools spanner S10, slotted screwdriver, copper
hammer, round punch, jack

Special tool for nut adjustment, rivet gun, special

Special tools
tool for return spring

Inspection tool Torque wrench (0~750 N·m), feeler gauge

Auxiliary materials Lithium base grease

(II) Operation steps

Removal
1. Fix the wheels.
2. Tilt the cab.
3. Jack the front axle.
4. Remove the front brake drum.
Refer to Replacement of Front Brake Drum.
5. Remove the brake shoe assembly.
1). Remove the return spring with the
special tool for the return spring of
brake shoe;
Notice: Tie the brake shoe with a ring or
iron wire before removing the return
spring.

Replacement of Front Brake Friction Plate 15

Front Drum Brake

2). Remove 1 locking wire and 2 screws;

3). Remove the supporting pin shaft of

brake shoe and the brake shoe;
4). Take off the brake shoe assembly.

6. Remove the front brake friction plate.

1). Remove the elastic retainer ring;

2). Remove the roller pin and roller;

16 Replacement of Front Brake Friction Plate

 Front Drum Brake

3). Check the wear conditions of front

brake friction plate;
 The thickness of front brake friction
plate shall be higher than the rivet
fixed surface.
Notice: Replace the front brake friction
plate when it is worn over the limits or
unbalanced seriously.

4). Place the brake shoe assembly

between 2 sleepers;
5). Remove the rivets with a round punch;
6). Remove 2 friction plates from the brake
shoe.

Installation
1. Install the front brake friction plate.
1). Wipe the contact area between brake shoe and friction plate to remove the dirt and rust
on them;
2). Place a new friction plate on the brake shoe and align it with the rivet hole;
3). Install rivets and rivet them firmly.
Notice: 1. The rivet must fully fill the riveting hole of brake shoe.
2. There shall be no clearance at the riveting position between brake shoe and friction
plate.
3. There shall be no clearance between the riveting joint and the countersunk hole of
friction plate.

2. Install the brake shoe assembly.

1). Apply lithium base grease on the
surface of brake shoe bushing;

Replacement of Front Brake Friction Plate 17

Front Drum Brake

2). Apply lithium base grease on the

surface of shoe shaft and fix the brake
shoe assembly with the shoe shaft;
3). Screw 2 screws, and fix them with 1
locking wire;

4). Install the return spring with the special

tool for the return spring of brake shoe.
3. Install the front brake drum.
Refer to Replacement of Front Brake Drum.
4. Lower the front axle.
5. Adjust the brake clearance.
Refer to Brake Clearance Adjustment.
Standard dimension: 0.3~0.5 mm
6. Lower the cab.

Check on Vehicle
1. Start the engine.
Inflate the air reservoir to make sure the air pressure is above 700 kPa.
2. Check the braking performance.
Check the braking process for any seizing, abnormal noise, etc.

18 Replacement of Front Brake Friction Plate

 Front Drum Brake

VII. Replacement of Front Brake Bottom Plate

(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Sleeve S10/S18/S21, double offset ring

Common tools
open-end spanner S10, jack, copper hammer

Special sleeve for wheel nut, special tool for

Special tools
return spring

Inspection tool Torque wrench (0~750 N·m), feeler gauge

Auxiliary materials Lithium base grease

(II) Operation steps

Removal
1. Fix the wheels.
2. Tilt the cab.
3. Jack the front axle.
4. Remove the front brake drum.
Refer to Replacement of Front Brake Drum.
5. Remove the front adjuster assembly.
Refer to Replacement of Front Adjuster Assembly.
6. Remove the brake shoe assembly.
Refer to Replacement of Front Brake Friction plate.
7. Remove the front brake cam.
Refer to Replacement of Front Brake Cam.

8. Remove the steering knuckle arm.

1). Remove the cotter pin and grooved
nut;
2). Remove the steering knuckle arm
from the steering knuckle.

Replacement of Front Brake Bottom Plate 19

Front Drum Brake

9. Remove the front brake bottom plate

assembly.
1). Remove the ABS sensor;
2). Remove the fastening bolt between the
front brake bottom plate and front axle;
Notice: The lower two bolts are
combined to tighten the steering knuckle
arm.
3). Take off the rear dust cover and front
brake bottom plate assembly
respectively;

4). Remove the 4 bolts between rear dust

cover and front brake bottom plate;
5). Take off the front brake bottom plate
assembly.

Check
1. Check the front brake bottom plate
assembly.
1). Check the front brake bottom plate
assembly for deformation;
2). Check the front cam seat bushing in
front brake bottom plate assembly for
damage;
3). Check the screw hole and bolt hole of
front brake bottom plate for damage.

Installation
1. Install the front brake bottom plate
assembly.
1). Install the rear dust cover onto the front
brake bottom plate assembly with 4
bolts;
Tightening torque: 15~25 N·m

20 Replacement of Front Brake Bottom Plate

 Front Drum Brake

2). Install the rear dust cover and

front brake bottom plate
assembly onto the steering
knuckle with 2 bolts;
Tightening torque: 350~450
N·m
3). Install the ABS sensor.

2. Install the steering knuckle arm.

1). Install the steering knuckle
arm onto the steering
knuckle;
2). Tighten the grooved nut;
Tightening torque: 350~450
N·m
3). Install the cotter pin.

3. Install the front brake cam.

Refer to Replacement of Front Brake Cam.
4. Install the brake shoe assembly.
Refer to Replacement of Front Brake Friction plate.
5. Install the front adjuster assembly.
Refer to Replacement of Front Adjuster Assembly.
6. Install the front brake drum.
Refer to Replacement of Front Brake Drum.
7. Lower the front axle.
8. Adjust the brake clearance.
Refer to Brake Clearance Adjustment.
Standard dimension: 0.3~0.5 mm
9. Lower the cab.

Check on Vehicle
1. Start the engine.
Inflate the air reservoir to make sure the air pressure is above 700 kPa.
2. Check the braking performance.
Unscrew the air pipe at the inlet of front brake air chamber, at which there shall be air
pressure input when the brake pedal is stepped down and no input when the brake pedal is
released.

Replacement of Front Brake Bottom Plate 21