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Structure ...................................................................................................10 – 1
Brake System ............................................................................................10 – 1
Disassembly and Reassembly ...........................................................10 – 2
Master Cylinder .........................................................................................10 – 2
Disassembly ..........................................................................................10 – 2
Reassembly ...........................................................................................10 – 3
Wheel Brakes ............................................................................................10 – 4
Disassembly ..........................................................................................10 – 6
Reassembly ...........................................................................................10 – 9
Wheel Cylinder .......................................................................................... 10 – 12
Disassembly .......................................................................................... 10 – 12
Reassembly ........................................................................................... 10 – 13
Inspection and Adjustment ................................................................ 10 – 14
Automatic Adjuster Test ............................................................................. 10 – 14
Manual Adjustment .................................................................................... 10 – 14
Parking Brake Cable Adjustment ............................................................... 10 – 15
Brake Pedal Adjustment ............................................................................ 10 – 16
Bleeding Brake Lines ................................................................................ 10 – 17
Braking Performance Test .......................................................................... 10 – 17 10
Parking Brake Lever .................................................................................. 10 – 18
Troubleshooting ..................................................................................... 10 – 19
Service Data ............................................................................................. 10 – 21
BRAKE SYSTEM
Structure
Brake System
Reservoir tank
Brake pedal
Wheel brake
210740
10-1
BRAKE SYSTEM
Master Cylinder
Disassembly
3
1
2 ❋
9
✩
8
✩
4 5 6
❋ ❋ ❋ 7
209783
Sequence
1 Clevis, Nut, Push rod 6 Valve seat
2 Boot 7 Cyliner
3 Snap ring 8 Bushing
4 Piston assembly 9 Filler union
5 Valve assembly
NOTICE: The parts (i ) and (G ) to be changed periodically are included in the Repair Kit.
10-2
BRAKE SYSTEM
1. Cylinder
(1) Check the cylinder bore for rusting, erosion, abnormal
wear, or scoring.
(2) Check the inlet and relief ports for restriction. Check
the threads on each joint for damage. Also, check the
boot and other parts for damage.
2. Piston
Check the piston for damage. Replace if it is damaged.
Insert the piston into the cylinder, and measure the piston-
to-cylinder clearance. If the clearance is in excess of the
service limit, replace the cylinder and piston.
A: Standard value B: Service limit
0.020 to 0.105 mm
Clearance between A
(0.00079 to 0.00413 in.)
cylinder and piston
B 0.15 mm (0.0059 in.)
3. Return spring
Replace the spring if it is severely damaged or its free
length is at or less than the service limit.
A: Standard value B: Service limit
A 59.2 mm (2.33 in.)
Spring free length
B 53.9 mm (2.12 in.)
Reassembly
To reassemble, follow the disassembly procedure in
reverse, paying attention to the following points.
(1) Wash all metal parts clean with volatile cleaning
solvent, and completely dry them with compressed air.
(2) Apply a thin coat of rubber grease exclusively designed
for brake components or brake fluid to the cylinder
bore, piston cups, and the inner face of the filler union
bushing mounting hole.
10-3
BRAKE SYSTEM
4 3 6 11 9 1 2 7 12 5
A
10
10-4
BRAKE SYSTEM
3 A 11
14
6
9
13
7
5
Drum 8
rotating
direction
during
forward
movement 10
10 10
12
4
Adjusting screw
rotating direction
1 to expand shoes
15
Section A – A
17 2 A
16
10-5
BRAKE SYSTEM
Wheel Brakes
Disassembly
10 9
9
12
1
11 ❋ 5
8 7
❋ 2
5 4
207208
Sequence
1 Return spring 7 Strut, Anti-rattle spring
2 Cable with spring 8 Shoe and lining (primary), Parking brake lever,
3 Hold-down spring, Cup, Pin Retainer, Spring washer
4 Adjusting lever, Adjusting spring, Return spring 9 Wheel cylinder
5 Cable guide, Sheave, Adjusting screw, Pin, 10 Parking brake cable
Washer 11 Mounting bolt, Spring washer
6 Shoe guide plate, Shoe and lining (secondary) 12 Backing plate
Start by:
(a) Remove the front wheel.
(b) Remove the wheel hub and brake drum.
(c) Separate the parking brake lever and cable at the
bottom of the wheel brake.
(d) Disconnect the brake pipe from the wheel brake
assembly.
10-6
BRAKE SYSTEM
200271
200272
1. Backing plate
(1) Check the backing plate for cracks.
4.87 mm 5.7 mm
A
Thickness of (0.19 in.) (0.22 in.)
linings 1.0 mm 1.0 mm 203005
B
(0.04 in.) (0.04 in.)
10-7
BRAKE SYSTEM
3. Brake drums
Check the inside (friction) surface of the drum for
abnormal wear, grooving and other defects. Minor
grooving can be removed by grinding, provided that the
inside diameter does not exceed the service limit.
254 mm 310 mm
A
Inside diameter (10.0 in.) (12.2 in.)
of brake drum 256 mm 312 mm
B
(10.1 in.) (12.3 in.)
4. Adjusting screws
Check the wheel teeth for wear. Turn the screw by hand to
see if its rotating parts turn smoothly.
200274
6 Other parts
(1) Check the shoe return springs for cracks or fatigue.
(2) Check the adjusting springs for cracks or fatigue.
(3) Check the cable with spring for stretching.
10-8
BRAKE SYSTEM
Reassembly
1 ton class
4 3 7 5 12 10 1 2 12 8 13 6
A
11
14 Section A – A
A
203586
Sequence
1 Wheel cylinder 9 Hold-down spring, Cup, Pin
2 Backing plate 10 Shoe guide plate
3 Shoe and lining (primary) 11 Cable with spring
4 Parking brake lever 12 Return spring
5 Retainer, Washer 13 Cable guide, Sheave, Pin, Washer
6 Shoe and lining (secondary) 14 Adjusting lever, Adjusting screw, Return spring
7 Strut
8 Anti-rattle spring
10-9
BRAKE SYSTEM
2, 3 ton classes
3 A 11
14
6
9
13
7
5
8
10
10 10
12
4
15
Section A – A
17 2 A
16
Sequence
1 Backing plate assembly 9 Strut, Anti-rattling spring
2 Parking brake cable, Snap ring 10 Pin, Hold-down spring, Cup
3 Wheel cylinder 11 Shoe guide plate
Prepare Parts 4, 5 and 6 in assembly beforehand. 12 Cable with spring
4 Parking brake lever 13 Return spring (primary)
5 Primary shoe and lining assembly 14 Return spring (secondary)
6 Retainer, Washer 15 Adjusting lever, Adjusting spring
Prepare Parts 7 and 8 in assembly beforehand. 16 Adjusting screw
7 Pin, Sheave, Washer 17 Return spring
8 Secondary shoe and lining assembly
10-10
BRAKE SYSTEM
Left-half parts
Plated in whitish color 200277
(right-hand thread)
Right-half parts
Plated in yellowish color
(left-hand thread)
10-11
BRAKE SYSTEM
Wheel Cylinder
Disassembly
2
3
5
6
❋
7
4
3
2
1
200278
200279
Sequence
1 Connector link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup
10-12
BRAKE SYSTEM
1. Cylinder body
(1) Check the bore for rusting, erosion or scoring.
(2) Check the threads of the bleeder screw and oil pipe for
damage.
2. Pistons
(1) Check the sliding surface for rusting or scratching.
(2) With the piston installed in the cylinder body, measure
the piston-to-cylinder clearance. Replace if the
clearance is in excess of the service limit.
A: Standard value B: Service limit
0.020 to 0.105 mm
Clearance between piston A
(0.00079 to 0.00413 in.)
and cylinder 200280
B 0.15 mm (0.0059 in.)
3. Piston cups
Check for swelling, damage or other defects. Replace the
cup if defective even slightly.
A: Standard value B: Service limit
Reassembly
To reassemble, follow the disassembly procedure in
reverse, paying attention to the following points.
(1) Wash all metal parts clean with volatile cleaning
solvent, and completely dry them with compressed air.
(2) Apply a thin coat of rubber grease exclusively designed
for brake components or brake fluid to the cylinder
bore and piston cups.
(3) Be careful not to damage the lips of the cups.
(4) Make sure that the cups face the correct directions
when reassembled.
(5) Tighten the bleeder screw to the specified torque.
10-13
BRAKE SYSTEM
Manual Adjustment
Using a screwdriver through a hole on the back of the
backing plate, adjust the drum-to-lining clearance to
specification by rotating the adjusting screw wheel.
NOTICE: Turning the wheel by one tooth corresponds to a
change of 0.03 mm (0.0012 in.) (1 ton class),
0.025 mm (0.0010 in.) (2, 3 ton classes) in shoe
diameter.
200283
10-14
BRAKE SYSTEM
Unit: mm (in.)
Truck Model 1 ton 2, 3 ton
Item class classes
10-15
BRAKE SYSTEM
209787
Unit: mm (in.)
Truck Model 1 ton 2, 3 ton
Item class classes Master cylinder 210741
Pedal height from floor A 182 to 200 (7.17 to 7.87)
0.5 to 1.0
Clearance B
(0.020 to 0.039)
Push rod-to-piston Clearance B
1 (0.04)
clearance
1.5 to 6.5 1.5 to 5.5
Pedal play C
(0.059 to 0.256) (0.059 to 0.217)
Detail B 209789
10-16
BRAKE SYSTEM
NOTE
(a) Take care to maintain the brake fluid in the
reservoir tank at sufficient levels while the
bleeding operation is in progress.
(b) Use only the brake fluid of specified brand and
grade. Avoid mixing different types of fluids.
10-17
BRAKE SYSTEM
Applied
Released
1
2
209790
Reassembly
With the parking brake cable and lever connected, the force
required to pull the lever should be 245 to 295 N (25 to 30
kgf) [55 to 66 lbf].
Release
Adjustment
(1) Put the lever to the release position.
(2) Turn the rod clockwise to increase the lever’s tension;
counterclockwise to decrease it. Rod
103628
10-18
BRAKE SYSTEM
Troubleshooting
Oil leaking past primary cup in master *Replace piston cup(s) if cylinder
cylinder is free from unacceptable wear.
Replace the cup(s) and fluid
Oil leaking past cups in wheel cylinder with genuine parts if the cup(s)
Lack of braking is distorted.
force Oil leaking from oil pipe connection Retighten, or replace pipe and
connector.
Shoe linings worn Replace.
Shoe linings dirty with oil or grease Clean or replace.
10-19
BRAKE SYSTEM
Lever stroke is
Lining to drum clearance too small Readjust.
too small
10-20
BRAKE SYSTEM
Service Data
A: Standard value B: Service limit
Unit: mm (in.)
Truck Models
1 ton class 2, 3 ton classes
Items
4 2 5
1 3
211125
10-21
BRAKE SYSTEM
4
2
4 secondary spirng
Free length
204962
10-22