Chapter 9 Brake System Overview

CHAPTER 9 BRAKE SYSTEM
Chapter 9 BRAKE SYSTEM

1. Structure of the Brake System
1 2
13 5
12
7
11
8
10
9
501833
1. Hydraulic tank 8. Parking brake
2. Transmission 9. Left side wheel brake
3. Parking brake valve 10. Front axle
4. Brake pedal 11. Right side wheel brake
5. Stop lamp switch 12. Gear pump for brake system
6. Wheel brake valve 13. Hydraulic gear pump
7. Pressure switch
The wheel brake has a brake drum on each side of the front
axle. The parking brake with wet multi-disc brakes (negative
brakes) is located within the transmission. A gear pump in
the braking system uses hydraulic oil from the braking
system to generate pressure to activate the wheel brakes
and the parking brake.
R CAUTION
DO NOT use brake oil, use hydraulic oil.
9-1
6
1 4) 5)
4 3)
2
7)
6)
5
3 5) 9
4)
3)
2) 10
11
14
7 1) 7) 12
6)
5)
15 8)
16
18
13
8 20
19 21
501834
1. Brake pedal 16. Parking brake switch
2. Stop lamp switch 17. VCM
3. Wheel brake valve 18. Brake piston
4. Rear combination lamp 19. Parking brake (inside the transmission)
5. Fuse 20. Pressure switch
6. Parking brake valve 21. Meter Panel
7. Right side wheel brake 1) A port
8. Left side wheel brake 2) T port
9. Gear pump for brake system 3) T1 port
10. Hydraulic tank 4) T2 port
11. Parking brake valve 5) P port
12. Pressure reducing valve 6) PKB port
13. Parking brake solenoid 7) BR port
14. Main relief valve 8) Emergency relief port
15. Orifice
9-2
When the brake pedal of emergency relief port is not When the parking brake switch is pushed or the engine is
pressed, pressure in the hydraulic circuit rises so that the stopped, the reducing valve in the parking brake closes.
main relief valve in the parking brake valve is activated to Disks inside the parking brake in the transmission are
return hydraulic oil to the hydraulic tank from the T2 port. pressed by springs while the gear is fixed to the output
When the brake pedal is pressed, the wheel brake valve shaft. As a result the track is stopped. When the hydraulic oil
feeds hydraulic oil to the right and left wheel brake cylinders pressure in the parking brake circuit becomes low, the
to activate the wheel brakes to stop the truck. At this time, pressure switch is activated to glow the parking brake
the valves in the braking system are activated in proportion warning lamp in the meter panel.
to the foot pressure applied to the brake pedal, which vary
the oil pressure to the wheel cylinders. The more foot
pressure applied to the brake pedal, the more hydraulic
pressure increases, which results in more braking power
generation. When the parking brake switch on the seat is
pulled, an electric signal is sent to the solenoid of the
parking brake valve, through the VCM. The solenoid valve
opens, and then the decompressed hydraulic oil at the
reducing valve is fed from a PKB port to the parking brake in
the transmission. Inside the parking brake, the brake piston
moves and presses the springs to release the brake disks so
that the parking brake is released.
9-3
4 5
8
6 7
A P BP
PKB
T
3 T1
T2 P 9
1
11
12 10
13
2
PB
14
1) 19 15
16
T 17
2) 18
501835
1. Front axle 12. Gear pump for brake system
2. Left side wheel brake 13. PTO section
3. Right side wheel brake 14. Pressure switch
4. Wheel brake valve 15. Parking brake section
5. Parking brake valve 16. Transmission
6. Relief valve section 17. Hydraulic tank
7. Pressure reducing and depressure valve section 18. Suction strainer
8. Parking brake emergency relief port 19. Wheel brake actuation
9. Orifice 1) Wheel cylinder pressure
10. Hydraulic gear pump 2) Petal stroke (piston stroke)
11. To hydraulic control valve
The schematic chart above shows the oil pressure circuit for
the wheel brakes and the parking brake. Oil pressure from
the wheel brake valve to the wheel cylinder acts on the
brake pedal stroke as shown in the graph above.
9-4
1.1 Wheel Brake
4.0 to 4.5 ton classes
7
A 1
9 5
3 10
1) 6
4
2)
13 11
12 A A-A
501836
1. Wheel cylinder 9. Return spring
2. Backing plate assembly 10. Sheave
3. Shoe and lining assembly (primary) 11. Adjusting lever
4. Shoe and lining assembly (secondary) 12. Adjusting screw
5. Return spring 13. Return spring
6. Hold-down spring 1) Drum rotation when moving forward
7. Shoe guide plate 2) Adjusting screw rotation when the shoes are expanded
8. Fitting cable
Note: Shown in the figure is for the left.
9-5
5.0C to 5.5 ton classes
1
A 2
3
5
9
6
10
1)
8
4
2)
13 11
A
12
A-A
501837
1. Wheel cylinder 9. Return spring
2. Backing plate assembly 10. Toggle lever
3. Shoe and lining assembly (primary) 11. Adjusting lever
4. Shoe and lining assembly (secondary) 12. Adjusting screw
5. Return spring 13. Return spring
6. Link 1) Drum rotation when moving forward
7. Hold-down spring 2) Adjusting screw rotation when the shoes are expanded
8. Fitting cable
9-6
1.2 Parking Brake Valve
2
3
B A
(B)
1) 3)
5) (B)
B
4) 7
2 1
A 4
3
5 7
6
4
2 A-A 501838
1. Parking brake valve block 1) T1 port
2. Solenoid valve block 2) T2 port
3. Main relief valve 3) P port
4. Solenoid valve assembly 4) PKB port
5. Pressure reducing valve 5) BR port
6. Orifice
7. Emergency relief port
9-7
2. Structure of Wet Disk Brakes
Brake system (wet disk brakes)
10
2
7
3
4 8
5 4
501839
1. Sub-tank 6. Parking brake valve
2. Oil filter assembly 7. Accumulator
3. Gear pump 8. Stop lamp switch
4. Wet disc brake assembly 9. Brake valve
5. Automatic deceleration valve (option) 10. Air breather
9-8
Wet disc brakes
11
8
T/M
10
9
4.9 MPa
12
P
7
PKB
T
Ø0.6
7.3 MPa
6
13
ACC P
BR
5
P
T
4
A
1)
2)
2)
1)
1
2
3
501840
1. Brake unit (right) 9. Oil tank (max. 8.9 L (2.35 US gal))
2. Brake unit (left) 10. Pressure switch
3. Connector 11. Engine
4. Brake valve 12. Gear pump (discharge rate: 4.46cc (0.27 cu.in.)/rev)
5. In-line filter 13. Accumulator
6. Parking valve assembly 1) Cooler
7. Parking valve emergency relief port 2) Service
8. Level gauge
9-9
Wet disc brakes with option
T/M
11
10
8
4.9 MPa
12
P
7
PKB
T
Ø 0.6
7.3 MPa
6
13
ACC P
BR
5
P
T
4
A
㧳
㧭
2)
1)
1)
2)
B
T
P
2
1
14
502248
1. Brake unit (right) 9. Oil tank (max. 8.9 L (2.35 US gal))
2. Brake unit (left) 10. Pressure switch
3. Connector 11. Engine
4. Brake valve 12. Gear pump (discharge rate: 4.46cc (0.27 cu.in.)/rev)
5. In-line filter 13. Accumulator
6. Parking valve assembly 14. Electromagnetic proportional pressure reducing valve
7. Parking valve emergency relief port (option)
8. Level gauge 1) Cooler
2) Service
9-10
2.1 Wet Disc Brake Assembly
12 17
14 A 18
15
13
B
3 19 A
9 16
4 5 6 2 1
A-A 7
10
11 8
B-B 501842
1. Piston housing 11. Spring guide
2. Brake housing 12. Return plate
3. Brake cover 13. Gauge rod
4. Mating Plate 14. Brake bleeder
5. Friction plate 15. Force feed lubricating bleeder
6. End plate 16. Drain plug
7. Brake piston 17. For brake pipe (M12 X 1)
8. Piston ring 18. Inlet for forced feed lubrication (M12 x 1)
9. Plug 19. Outlet for forced feed lubrication (G1/2 x 1)
10. Return spring
Note: The illustration shows a left-hand wet disc brake
assembly.
9-11
2.2 Parking Brake Valve (Wet Disk Brakes)
2) 5
1) 1
5)
4
3) 6
4)
501843
1. Parking brake valve block 1) T port
2. Relief valve 2) P port
3. Solenoid valve 3) BR port
4. Strainer 4) PKB port
5. Orifice 5) ACC port
6. Emergency relief port
9-12
2.3 Auto Deceleration Valve (Wet Disk Brake Option)
2
3
1
4)
2)
1)
5)
3)
501844
1. Block 1) A port
2. Solenoid valve 2) B port
3. Shuttle valve 3) G port
4) T port
5) P port
9-13
3. Disassembling and Reassembling Wheel Brake
3.1 Disassembling Wheel Brake (4.0 to 4.5 classes)
Preparation
(1) Remove the front wheel. Refer to "Front Axle and
Reduction Differential."
(2) Remove the wheel hub and brake drum.
(3) Place a pan to catch the brake oil and remove the brake
pipe from the wheel brake assembly.
Disassembly sequence
11
9
7
1
5
3
10 6
8
2
5
501845
1. Return spring 6. Shoe guide plate
2. Fitting cable 7. Shoe and lining assembly (secondary)
3. Hold-down spring, Cup, Pin 8. Shoe and lining assembly (primary)
4. Adjusting lever, Adjusting spring, Return spring 9. Wheel cylinder, Breeder, Bolt
5. Sheave, Adjusting screw, Washer 10. Mounting bolt, Spring washer
11. Backing plate
9-14
3.2 Disassembling Wheel Brake (5.0C to 5.5 classes)
Preparation
(1) Remove the front wheel. Refer to "Front Axle and
Reduction Differential."
(2) Remove the wheel hub and brake drum.
(3) Place a pan to catch the brake oil and remove the brake
pipe from the wheel brake assembly.
(4) Remove the mounting bolts and remove the wheel
brake assembly from the front axle housing.
12 10
10
13
11 8
2 1
7 1
5
4
13 3
4 6
7 501846
1. Return spring 8. Shoe and lining assembly (secondary)
2. Link 9. Shoe and lining assembly (primary)
3. Fitting link 10. Wheel cylinder, Bleeder, Bolt, Spring washer
4. Hold-down spring, Cup, Pin 11. Mounting bolt, Spring washer
5. Toggle lever, Split pin, Plain washer 12. Dust shield
6. Adjusting lever, Adjusting spring, Return spring 13. Backing plate, Bolt
7. Adjusting screw, Cover
9-15
Suggestions for disassembly

(1) Removing return spring
Remove the return spring from the shoe guide plate
using special tool.
1
501847
1. Spring remover
Special tool
Spring remover 91K67-00100
(2) Removing hold-down spring

Remove the shoe hold-down spring from backing plate
using a special tool. 1
501848
1. Spring retainer
Special tool
4.0 to 4.5 ton classes 91M67-00100
Spring retainer
5.0C to 5.5 ton classes 91N67-00100
(3) Removing shoe and lining only To remove the wheel

brake assembly, the wheel hub and brake drum must
be removed as is conventionally done, but to remove 1)
the shoe and lining assembly only, the brake drum is
the only part you need to remove.
- Remove the front wheel.
- Remove the brake drums.
- Turn the adjustment screw to the minimum.
Note: When it is difficult to turn the adjusting screw, turn it
from behind through the backing plate's adjustment
hole. (Refer to "Manual adjustments.") 1
- Rotate the wheel hub, and remove the return spring, 501849
adjusting spring, and hold-down spring with a tool 1. Notched portion 1) Rotate the wheel hub.
through the wheel hub.
9-16
- Remove the adjusting lever, and fitting cable or fitting

link. 1)
1 2
- Remove the shoe and lining assemblies (primary and
secondary), and adjusting screw.
3
501850
1. Return spring mounting 3. Hold-down spring
portion 1) 4.0 to 4.5 ton classes
2. Hold-down spring
1)
1
501851
1. Return spring mounting 1) 5.0C to 5.5 ton classes
portion
2. Hold-down spring
Inspection and adjustment after disassembling

wheel brake
(1) Backing plate
- Check the backing plate for cracks and distortions.
(2) Shoe and lining assembly
- Check shoes and linings for cracks or damage.
- Replace the lining with a new one if it is grease-
stained, burned, or deformed.
- Measure the thickness of the lining and if the service
limit is exceeded, replace the lining. If the service limit
is likely exceeded by the time of next inspection, 501852
replace the lining with a new one.
Lining thickness Standard value Service limit

4.0 to 4.5 ton classes 5.62 mm (0.2213 in.) 1.0 mm (0.039 in.)
5.0C to 5.5 ton classes 10.0 mm (0.394 in.) 1.0 mm (0.039 in.)
9-17
- For riveted linings (5.0C to 5.5 ton classes trucks),

replace the lining when the lining thickness above
rivet head becomes 1 mm (0.04 in.).
501853
Note: Should not reach rivet's
head at any points.
(3) Brake drum

Grind the inner surface of the brake drum if local wear
or any flaws are present.
Inside diameter of brake drum Standard value Service limit

4.0 to 4.5 ton classes
317.5 mm (12.500 in.) 318.5 mm (12.539 in.)
5.0C to 5.5 ton classes
(4) Adjusting screw

Check the wheel teeth for wear, and check that each
part of the adjusting screw turns smoothly.
501854
(5) Inspecting other parts

- Check the shoe return springs for cracks or settling.
- Check the adjusting springs for cracks or settling.
- Check the fitting cable for overstretching, wear and
break (4.0 to 4.5 ton class).
9-18
3.3 Reassembling Wheel Brake (4.0 to 4.5 ton classes)
Reassembly sequence
6
A 1
8
8
9
3
7
5
A A-A
10
501855
1. Wheel cylinder 7. Fitting cable
2. Backing plate assembly 8. Return spring
3. Shoe and lining assembly (primary) 9. Cable guide, Sheave, Pin, Washer
4. Shoe and lining assembly (secondary) 10. Adjusting lever, Adjusting screw, Adjusting spring
5. Hold-down spring, Cup, Pin
6. Shoe guide plate
9-19
3.4 Reassembling Wheel Brake (5.5C to 5.5 ton classes)
Reassembly sequence
10
1
A 2
3
8
8
A-A
A
9
501856
1. Wheel cylinder 7. Fitting cable
2. Backing plate assembly 8. Return spring, Link
3. Shoe and lining assembly (primary) 9. Adjusting lever, Adjusting screw, Adjusting spring
4. Shoe and lining assembly (secondary) 10. Dust shield
5. Hold-down spring, Cup, Pin
6. Toggle lever, Split pin, Plain washer
9-20
Suggestions for reassembly

(1) Installing wheel cylinder
Install the wheel cylinder to the backing plate by
tightening it to the specified torque.
501857
Tightening torque
17.65 to 26.48 N·m (1.800 to 2.700 kgf·m) [13.0180 to 19.5306 lbf·ft]
(2) Applying grease

Apply a thin coat of the brake grease (AKB100) to the 1) (a) (b)
following areas. (e)
- Shoe ledge (6 places) (Contact surface between the
backing plate and the shoe) (b)
(b) (a)
(d) (a)
(h)
(h) (a)
(a)
(a)
501858
1) 4.0 to 4.5 ton classes
- Contact surface of the shoe web and the anchor pin of

the backing plate (4.0 to 4.5 ton class).
- Contact surface of the shoe web and the backing
plate grooves (5.5C to 5.5 ton class).
- Hold-down spring cup and shoe contact surfaces
- Contact between the fitting cable and the sheave, and
1 2
the pin (4.0 to 4.5 ton class).
- Contact between the fitting cable and the sheave, and
the pin (5.5C to 5.5 ton class).
- Adjusting lever and pin contact surfaces
1) 2) 501859
1) 4.0 to 4.5 ton classes 1. Contact between anchor pin
2) 5.5C to 5.5 ton classes and shoe web
2. Contact between grooves and
show web
(3) Installing shoe and lining assembly

Make sure that each connector link of the wheel
cylinder is properly installed in the shoe web.
(4) Installing return spring
Using the special tool, install the return springs to the
backing plate pins.
1)
501860
1. Spring hook
9-21
Special tool
Spring installer 65309-15413
(5) Installing automatic adjuster

- Clean each part of the adjusting screws and apply
grease to the threaded portion and the screw socket
mounting surface. Make sure that the screws turn
easily by hand. If the screw movement is tight, replace
it with a new one.
- Identification of adjusting screw (mark)
- Left side (left-hand thread) = LH
- Right side (right-hand thread) = RH
Note: After reassembly, bleed air out of the brake oil lines.
Refer to "Inspection and Adjustment."
(6) Installing dust shield Tighten the bolts to the specified
torque.
Tightening torque
(7) Installing brake drum

Tighten the wheel nuts with the utmost care, because
the wheel nuts hold the brake drums and the front
wheels together. (For brake drum installation, refer to
"Front Axle and Reduction Differential."
9-22
4. Disassembling and Reassembling Wheel Cylinder
4.1 Disassembling Wheel Cylinder (4.0 to 4.5 ton class)
3
*4
6
*5 1
2
*
*4
*3
2
1 *
501861
1. Connector link 5. Return spring*
2. Boot* 6. Breeder screw, Cap
3. Piston* 7. Cylinder body
4. Piston cup*
Note: The parts marked * are included in the repair kit.
9-23
4.2 Disassembling Wheel Cylinder (5.5C to 5.5 ton classes)
6 3
*4
1
2
*
*4
*3
7
5
*
2
1 *
501862
1. Connector link 5. Return spring*
2. Boot* 6. Breeder screw, Cap
3. Piston* 7. Cylinder body
4. Piston cup*
Note: The parts marked * are included in the repair kit.
9-24
4.3 Inspecting and Correcting Wheel Cylinder After Disassembling
(1) Cylinder body

- Check the inner surface of the cylinder bore for rust,
erosion or scratches.
- Check threads of both the bleeder screw and oil pipe
for damage.
(2) Piston
- Check the outer surface of the piston for rust and
scratches.
- Install the piston inside the cylinder body and
measure the clearance between the piston and
cylinder body. Replace the piston with a new one if its
clearance exceeds the service limit.
501863
Item Standard value Service limit

Inside diameter of brake drum 0.020 to 0.105 mm (0.0008 to 0.0041 in.) 0.15 mm (0.0059 in.)
(3) Piston cup

Check the piston cup for swelling and damage, and
replace the cup with a new one if any damage is found,
even if it is slight one.
Item Standard value Service limit

Interference between piston cup and cylinder body 1.85 mm (0.0728 in.) 0.65 mm (0.0256 in.)
(4) Boot
Replace the boot with a new one if there is damage or
degradation.
1 1)
Note: Because this brake system uses mineral oil, instead of
brake oil, the materials used for boots, piston cups,
and bleeder cups are different from those used in
conventional models. The illustration on the right
shows how to identify the new ones. 2)
2
3
501864
1. Boot 1) Change in shape
2. Piston cup 2) "NBR" mark raised on the side
3. Bleeder cap face
9-25
4.4 Reassembling Wheel Cylinder
For reassembly, follow the disassembly sequence in reverse

while noting the following instructions.
(1) Clean metal parts with a volatile metal cleaning fluid
and blow off the fluid completely with compressed air.
(2) Apply a thin layer of brake rubber grease or brake oil to
the cylinder inner surface and piston cup.
(3) Be careful not to damage the lip of piston cup.
(4) Pay attention to the orientation of piston cup when
installing.
(5) Tighten the bleeder screw to the specified torque.
Tightening torque
9-26
5. Disassembling and Reassembling Parking Brake Valve
5.1 Disassembling Parking Brake
5 3
4
1
3
501865
1. Solenoid valve assembly 4. Orifice
2. Main relief valve 5. Parking brake valve block
3. Spool, Slug, Spring
Inspection and adjustment after disassembling

parking brake valve
(1) Inspection of spring
(2) Check springs for cracking and settling.
9-27
5.2 Reassembling Parking Brake
Reassembly sequence
(1) Tighten each part to the specified torques as shown for
reassembly.
4
5
501866
Rer. Tightening torque

1 6 to 8.0 N. m (0.61 to 0.82 kgf·m) [4.43 to 5.90 lbf·ft]
2 6 to 8.0 N. m(0.61 to 0.82 kgf·m) [4.43 to 5.90 lbf·ft]
3 34.3 to 39.2 N. m(3.5 to 4.0 kgf·m) [25.30 to 28.91 lbf·ft]
4 24.5 ± 2.5 N. m(2.50 ± 0.25 kgf·m) [18.07 to 1.84 lbf·ft]
5 24.5 ± 2.5 N. m(2.50 ± 0.25 kgf·m) [18.07 to 1.84 lbf·ft]
9-28
6. Disassembling and Reassembling Wet Disk Brake Assembly
6.1 Disassembling Wet Disk Brake Assembly
13
2
12 5 1
7
10
1716 4
15
19
18
9
11
14
6
20 7
8
501857
1. Brake cover 11. Spring guide, Return spring
2. O-ring 12. Gauge plug, O-ring, Gauge rod, O-ring
3. Mating plate 13. Breeder screw, Cap
4. Friction plate 14. O-ring
5. End plate 15. Piston ring
6. Brake housing 16. Ring seal
7. O-ring 17. O-ring
8. Snap ring, Plain washer 18. Brake piston
9. Return plate 19. Piston seal
10. Plug, O-ring 20. Piston housing
Note: The illustration shows a left-hand wet disc brake
assembly.
9-29
Preparation
(1) Remove the front wheel.
Note: Refer to "FRONT AXLE AND REDUCTION
DIFFERENTIAL".
(2) Place a container, then remove a brake pipe and cooler
return hose from a wet disc brake assembly.
(3) Remove the wheel hub and wet disc brake assembly.
Note: For disassembling inspection, and assembling of a
wheel hub and wet disc brake assembly, refer to
"FRONT AXLE AND REDUCTION DIFFERENTIAL."
(4) Remove the oil seal retainer from the tube assembly
using a puller. 1
(5) Remove the O-ring from the oil seal retainer.
(6) Remove the wet disc brake assembly after removing
2 4
the mounting bolt.
3 6
5 501868
1. Axle support 4. Wet disc brake assembly
2. Front axle tube 5. Oil seal retainer
3. O-ring 6. O-ring
(7) Remove the floating seal from the wet disc brake
assembly.
(8) Remove the brake cover and O-ring from the wet disc 1
brake assembly.
2
3
501869
1. Floating seal 3. O-ring
2. Brake cover 4. Wet disc brake assembly
(9) Remove the mating plates, friction plates, and end

plate.
Note: Record or note the order of mating plates, friction
1 2
plates, and end plate as you remove them for correct
reassembly.
- Mating plate : 5
- Friction plate : 5
3
- End plate : 1
501870
1. Friction plate 3. End plate
2. Mating plate
9-30
(10) Remove the brake housing.

(11) Remove the O-rings.
1
2
3
4
501871
1. Brake housing 3. O-ring
2. O-ring 4. Piston housing
(12) Remove the snap ring and plane washer from the
return plate, and remove the return plate. 1
2
501909
1. Snap ring 3. Return plate
2. Plane washer
(13) Remove the gauge plug, gauge rod, and O-ring from
the piston housing. 1 7
(14) Remove the plug, O-ring, spring guide, and return
2 8
spring from the piston housing. 3 9
(15) Remove the drain plug, O-ring, and bleeder screw from 4 10
the piston housing. 11
5
6
501910
1. Plug 7. Gauge plug
2. O-ring 8. O-ring
3. Spring guide 9. Gauge rod
4. Return spring 10.Bleeder screw
5. Drain plug 11.Piston housing
6. O-ring
9-31
(16) Remove the brake piston, piston seal, piston ring, ring
seal, and O-ring from the piston housing. 7 1
2
3
4
5
6
501912
1. Brake piston 5. Ring seal
2. Piston seal 6. Piston housing
3. Piston ring 7. O-ring
4. O-ring
(17) Remove the axle support from the front axle tube.
1
2
501911
1. Front axle tube 2. Axle support
9-32
6.2 Inspecting and Adjusting Wet Disk Brake Assembly After Disassembling
Refer to "Inspection and Repair" of standard truck for the

following (1) to (3).
(1) Axle
(2) Axle shaft deflection
(3) Oil seal and oil seal retainer
(4) Wet disc brake assembly
Piston
Check the sliding areas for any wear or damage. If there are
surface flaws, polish, and wash the surface.
Brake housing and hub
Check the tooth faces for wear or damage.
Piston housing
Check the sliding surface of the piston for wear or damage.
Friction plate and mating plate

- Check for burn, uneven contact, deformation or
damage.
- Check mating plates for heat spots.
- Check the inner and outer teeth surfaces for wear or
damage.
- Measure the thickness of each plate.
Note: If the inspection finds a defect in any one of above,
replace all friction and mating plates with new ones.
Upon replacement, perform flushing.
501913
Item Standard value Limit value

Mating plate 2.00 ± 0.08 mm (0.0787 ± 0.0031 in.) -
Friction plate 3.7 ± 0.1 mm (0.146 ± 0.003 in.) 3.3 mm (0.130 in.)
Endplate 3.2 ± 0.1 mm (0.126 ± 0.003 in.) -
- Return spring
Measure the free length of return spring.
- Floating seal
Check the floating seal lip surface for damage, and
replace the lip if damaged.
501914
Item Standard value

Free length of return spring 24 mm (0.94 in.)
9-33
6.3 Reassembling Wet Disk Brake Assembly
(1) Clean the axle support mounting bolt, and apply the
sealing compound. 1
2
501911
1. Front axle tube 2. Axle support
Sealing compound
LOCTITE #271 or equivalent
(2) Install the axle support to the axle tube to the specified
torque.
Tightening torque
214 N·m (21.8 kgf·m) [157.84 lbf·ft]
(3) Wet Disk Brake Assembly, Disassembling

- Install the piston seal, piston ring, O-ring, ring seal to 1
4
the brake piston as shown. 2
Note: Apply oil (SAE 10W-30 Engine oil CD) to the brake
piston, piston seal, piston ring, O-ring, ring seal and
sliding surface.
5
3 501915
1. Piston ring 4. Brake piston
2. O-ring 5. Piston seal
3. Ring seal
- Install the brake piston and O-ring to the piston

housing. 1
Note: To install the brake piston assembly, insert it by hand. 2
501916
1. Brake piston assembly 3. Piston housing
2. O-ring
9-34
- Insert the return spring and spring guide from the

piston housing, and install the return plate, plain 1 2 3
washer and, snap spring.
- Install the O-ring to the piston housing. 7
4
6
5
501917
1. Return plate 5. Piston housing
2. Snap ring 6. O-ring
3. Plane washer 7. Spring guide
4. O-ring 8. Return spring
Note:
- Be sure to install O-rings.
- To install the snap ring, the opening of ring should be
oriented toward the outside. Also, face the rounded
side of snap ring downward.
1 1
2 2
502249
1. Snap ring 2. Washer
- Install the stud bolt to the brake housing as shown.
1
1) 2)
501918
1. Stud bolt 1) Left side
2) Right side
Item Tightening torque

Stud bolt 19.5 N·m (1.99 kgf·m) [14.382 lbf·ft]
9-35
- Install the brake housing to the piston housing, and

tighten the flange nut and bolt to the specified
torque.
501919

Bolt 137.3 ± 27.5 N·m (14.00 ± 2.80 kgf·m) [101.267 ± 20.28 lbf·ft]
Flange nut 73.5 ± 7.4 N·m (7.49 ± 0.75 kgf·m) [54.211 ± 5.45 lbf·ft]
- Using a special tool, install the end plate, friction

plates, and mating plates in the same order as they 1
were assembled.
- End plate : 1 2 3
- Friction plate : 5
- Mating plate : 5
5 4
501920
1. O-ring 4. Special tool
2. Friction plate 5. End plate
3. Mating plate
Special tool
Friction plate holder 91K67-03200
Note: Align the recesses of splines of friction plates (5

pieces).
- Install O-ring to the wet disc brake assembly.
501921
9-36
- Install the brake cover and O-ring to the wet disc

brake assembly to the specified torque. 1
2
3
502125
1. Hexagon socket bolt 3. Special tool
2. Brake cover 4. Wet disc brake assembly

Hexagon socket bolt 60.7 ± 12.1 N·m (6.19 ± 1.23 kgf·m) [44.770 ± 8.92 lbf·ft]
- Install the spacer, plug, and O-ring as shown to fix the

friction plates. Then, temporary tighten them to the 1 1
3
wet disc brake assembly.
1) 2 2) 502126
1. Air bleeder screw 1) Left side
2. Drain plug 2) Right side
3. Spacer insertion position
Spacer
91K33-17900
- Install the spacer to the gauge rod, and temporary

tighten it to the wet disc brake.
Spacer
91K33-17900
- Install the air breeder screw and drain plug to the wet
disc brake assembly by tightening them to the
specified torque.

Air bleeder screw 16.86 to 11.78 N·m (1.719 to 1.201 kgf·m) [12.4353 to 8.6885 lbf·ft]
Drain plug 19.6 ± 2.0 N·m (2.00 ± 0.20 kgf·m) [14.456 ± 1.47 lbf·ft]
9-37
- Install the taper plug to the wet disc brake assembly.
- Remove the friction plate holder from the wet disc
brake assembly.
1 1
2 3
502127
1. Spacer 3. Special tool
2. Tapered plug
9-38
7. Disassembling and Reassembling Parking Brake Valve (Wet Disk Brakes)
7.1 Disassembling Parking Brake Valve (Wet Disk Brakes)
6 5
7
501928
1. Parking brake valve block 5. Strainer
2. Relief valve 6. Orifice
3. Check valve 7. Plug for emergency relief port
4. Solenoid valve
9-39
7.2 Reassembling Parking Brake Valve (Wet Disk Brakes)
Reassembly sequence
(1) Tighten each part to the specified torques as shown for
reassembly.
6
3
8
5
7 9
4
10
11
502250
Rer. Tightening torque Rer. Tightening torque

34.3 to 39.2 N. m 19.6 ± 2.0 N·m
1 7
(3.50 to 4.0 kgf·m) [25.30 to28.91 lbf·ft] (2.0 ± 0.02 kgf·m) [14.46 ± 0.15 lbf·ft]
34.3 ± 3.4 N. m 34.3 ± 3.4 N·m
2 8
(3.50 ± 0.35 kgf·m) [25.30 ± 2.51 lbf·ft] (3.50 ± 0.35 kgf·m) [25.30 ± 2.51 lbf·ft]
39.2 ± 3.9 N·m 34.3 ± 3.4 N·m
3 9
39.2 ± 3.9 N·m 39.2 ± 3.9 N·m
4 10
19.6 ± 0.2 N·m 19.6 ± 2.0 N·m
5 11
34.3 to 39.2 N. m
6
(3.50 to 4.0 kgf·m) [25.30 to28.91 lbf·ft]
9-40
8. Disassembling and Reassembling Automatic Deceleration Valve (Wet Disk
Brake Option)
Automatic deceleration valve
502251
Option (ProShift, Auto-Deceleration)

1
4
2
3 502252
Rer. Tightening torque

1 16 to 23 N·m (1.6 to 2.3 kgf·m) [11.80 to 16.96 lbf·ft]
2 0.686 N·m (0.0700 kgf·m) [0.50597 lbf·ft]
3 49 ± 4.9 N·m (5.0 ± 0.49 kgf·m) [36.14 ± 3.61 lbf·ft]
4 39.2 ± 3.9 N·m (4.00 ± 0.39 kgf·m) [28.912 ± 2.87 lbf·ft]
9-41
9. Inspecting and Adjusting Brake System
9.1 Automatic Adjuster Test
(1) With the clearance between the lining and the brake
drum being set to the specification, pull the fitting
cable or the fitting link toward you with a finger. Then
the adjusting lever moves the adjusting screw wheel
one notch and returns to the original position.
501930
Item Drum inside diameter Drum-to-lining clearance

4.0 to 4.5 ton classes 317.5 mm (12.500 in.) 0.25 to 0.4 mm (0.0098 to 0.0157 in.)
5.0C to 5.5 ton classes 317.5 mm (12.500 in.) 0.4 to 0.6 mm (0.0157 to 0.0236 in.)
(2) If the adjusting lever does not release the adjusting

screw when the fitting cable or the fitting link returns, 1
or if the adjusting lever reacts slowly, check the position
of the adjusting lever. The adjusting screw lever is set at
approximately 9 mm below the centerline of the
adjusting screw so that the lever contacts the adjusting
screw wheel. If the adjusting screw lever is in the wrong
position, the lever does not engage with the teeth of
the adjusting wheel correctly, and as a result, the wheel
does not turn correctly.
2 501931
1. Adjusting screw wheel 2. Adjusting lever
(3) If the automatic adjuster does not work properly, follow

the instructions below.
- Ensure that the adjusting spring is correctly hooked to
the hole of the primary shoe.
- Replace the fitting cable or the fitting link with a new
one.
- Replace the adjusting lever with a new one.
- Replace the adjusting screw with a new one.
9-42
9.2 Manual Adjustment
(1) Remove the cover from the adjusting hole in the back
of the backing plate.
(2) Adjust the drum-to-lining clearance to the specification 1
by turning the adjusting screw wheel with two 1)
screwdrivers through the hole in the back of the
backing plate.
(3) Hold the adjusting lever with one screwdriver and turn
the wheel of the adjusting screw with the other 2)
screwdriver.
Note: The adjusting screw wheel can be adjusted by the
notch of the wheel. One notch equals 0.03 mm (0.001
in.) in diameter. 1 501932
1. Adjusting screw 1) Wide
2. Adjusting lever 2) Narrow
9.3 Adjustment of Brake Pedal
(1) Adjust the stopper bolt so that the brake pedal pad
height is approximately 270 mm (10.63 in.) from the 1)
center of the shaft, and secure the stopper bolt with the
lock nut. 1
(2) In order to secure a clearance of 1 mm (0.04 in.)
between the push rod and piston in the wheel brake 2
valve, adjust the distance from the clevis slot center to
the body edge to approx 110 mm (4.33 in.) by rotating
the push rod, and lock the clevis with the lock nut. Make 2)
sure the free play of the brake pedal is approximately 5
mm (0.2 in.) after the adjustment. 3)
501933
1. Stopper bolt 1) Free play: approx. 5mm (0.2 in.)
2. Lock nut 2) Approx. 270 mm (10.63 in.)
3. Clevis 4. Approx. 110 mm (4.33 in.)
9-43
9.4 Air Bleeding Wheel Brake (Wet Disc Brakes)
When any part of the brake oil lines has been disassembled
for repair, bleed air out of the lines. Air bleeding is a two-
man job.
Preparation
Brake oil should be hydraulic oil. Make sure there is enough
oil in the hydraulic tank before starting work.
(1) Block the wheels.
(2) Connect a transparent vinyl tube onto the bleeder

screw of the right-hand wheel cylinder, which is the
farthest wheel cylinder from the wheel brake valve.
(3) Place the other end of the vinyl tube into a container
filled with brake oil so that the tube end stays below the
oil surface level.
Note: Be sure to use a vinyl tube whose diameter is approx
7mm in the outside and 5 mm in the inside.
(4) Place the direction lever in the neutral, apply the
parking brake switch, and start the engine.
(5) After one person loosens the bleeder screw, the other
person depresses the brake pedal. 501934
(6) Make sure the brake oil is flowing through the vinyl
tube.
Note: While bubbles are seen in the brake oil, keep pressing
the brake pedal.
(7) When oil flow is free of air bubbles, tighten the bleeder
screw to the specified torque while the brake oil is
flowing.
Tightening torque
(8) Bleed air from left side cylinder wheel as well, by

repeating above procedure.
(9) Stop the engine after work is completed.
9-44
9.5 Air Bleeding Parking Brake
(1) Connect a transparent vinyl tube onto the bleeder

screw of the transmission. Place the other end of tube
into a container filled with brake oil.
(2) Start the engine and depress the brake pedal.
(3) While keeping the brake pedal depressed, release the
parking brake by pulsing the parking brake switch.
(4) Loosen the bleeder screw and tighten the bleeder

screw while the brake oil is flowing through the vinyl
tube.
(5) Repeat the above until the oil flow in the vinyl tube is
free of air bubbles.
(6) Push the parking brake switch, and stop the engine
after the air bleeding is completed.
Note: Check the hydraulic tank oil level after air bleeding.
501935
9.6 Changing and Refilling Brake Oil
Draining brake oil

(1) Remove the drain plugs from right and left disk brakes,
and drain oil from the tank.
Note: Place a pan to catch oil.
(2) Remove the return cooling hose, brake pipe, and
cooling pipe from the wet disk brakes, and drain oil.
1
502129
1. Drain plug
Periodic replacement interval

First month or 200 hours after purchase of new truck
Every 12 months or every 2000 hours
(3) After brake oil is drained, install the drain plug to the
sub-tank, and install the return cooling hose, brake
pipe, and cooling pipe to the wet disk brakes.
Note: Be sure to install properly so that no oil leaks from
connections when refilled.
1 502130
1. Return cooling hose
9-45
2
1
1) 2)
502131
1. Cooling 1) Left side
2. Brake 2) Right side

Drain plug 19.6 ± 2.0 N·m (2.00 ± 0.20 kgf·m) [14.456 ± 1.47 lbf·ft]
Return cooling hose 58.8 ± 5.9 N·m (6.00 ± 0.60 kgf·m) [43.369 ± 4.35 lbf·ft]
Brake pipe 16 to 23 N·m (1.6 to 2.3 kgf·m) [11.80 to 16.96 lbf·ft]
Cooling pipe 16 to 23 N·m (1.6 to 2.3 kgf·m) [11.80 to 16.96 lbf·ft]
(4) Replace the oil filter with new one.
1
502132
1. Oil filter
Periodic replacement interval

First month or 200 hours after purchase of new truck
Every 12 months or every 2000 hours
(5) Clean the PKB valve strainer.
Refilling brake oil

(1) Block the wheels, and pull the parking brake switch.
(2) Take out the level gauge, and add 10 liters of brake oil.
(3) Start the engine, and make sure oil level drops to
proper level.
(4) Bleed air from brake oil. Refer to “Brake Oil, Air
Bleeding."
502133
9-46
(5) Circulate oil through the brake line by repeating stop

and driving for 10 minutes.
(6) Stop the engine, and check the oil level with level
gauge. Make sure that oil level is in the middle of oil
mark range.
Note: To check oil level, start the engine to circulate the oil.
Oil level may rise in a while after stopping the engine,
but, that is no problem, provided that the oil level
stays within the oil mark range after the engine is
started.
9.7 Flushing and Air Bleeding Wet Disk Brakes
Flushing brake oil

Flush brake oil when disk plates of wet disk brakes (friction,
mating, and end plates) have been replaced.
Note: Flush so that flushing oil will not remain in the brake
system. If flushing oil remains in the brake system,
brake performance may be reduced.
Refilling flushing oil
(1) Drain the brake oil. Refer to “Draining brake cooling oil.”
(2) Block the wheels, and pull the parking brake switch.
(3) Take out the level gauge, and add 10 litters of brake oil.
(4) Start the engine, and make sure flushing oil drops in the
brake system.
Flush the brake oil system.
Flushing oil
10W oil
Flushing brake oil system preparation

Jack-up the front wheels, and place the jack stand under the
frame. Block the rear wheels.
(1) Release the parking brake.
(2) Depress the accelerator pedal all the way down and at
the same time, depress the brake pedal to run the truck
at speed of approximately 12 km/h, and keep this
condition for 10 seconds.
Note: This operation removes initial wear power of brake
disk.
(3) From the condition of step (2), release the brake pedal
for 5 seconds, and then repeat the step (2).
(4) Repeat steps (2) and (3) five times for both forward and
backward diving.
Draining flushing oil

(1) Drain the flushing oil. Refer to “Draining brake cooling
oil.”
Note: After flushing, drain flushing oil completely from the
brake system, by removing all pipes and hoses of the
brake system.
(2) Replace the oil filter with new one.
9-47
Procedure for bleeding air from the wet disc brake

(1) Add 10 liter of brake oil to the sub-tank.
Oil : Manufacturer's recommended oil
(2) Start the engine, and run at idling speed.
(3) Make sure that the oil level drops in the sub-tank. Then,
add oil so that the oil level is within the oil mark range
of the level gauge.
(4) Bleed air, feeding 50 kPa (0.5 kgf/cm2) from the service
brake bleeder and cooling bleeder. 2
- Service brake: Remove the brake pipe, and attach the 1
hose to the brake bleeder. Remove the internal air by
feeding 50 kPa (0.5 kgf/cm2). After air bleeding is
completed, tighten the brake pipe to the specified
torque.
- Brake cooling: Remove the cooling pipe, and attach
the hose to the cooler bleeder. Remove the internal
air by feeding 50 kPa (0.5 kgf/cm2). After air bleeding
is completed, tighten the cooling pipe to the specified 1) 2)
torque. 502131
1. Cooling pipe 1) Left side
2. Brake pipe 2) Right side

Brake pipe
16 to 23 N·m (1.6 to 2.3 kgf·m) [11.80 to 16.96 lbf·ft]
Cooling pipe
9-48
9.8 Air Leak Test
After reassembly, conduct air leak test before adding brake

oil. 1
Note: Air leak test must be conducted after disassembly and
reassembly in order to prevent brake oil leakage.
(1) Install an air compressor and joint with pressure gauge
into the lubricating hole of the wet disc brake.
(2) Apply a pressure of 0.15 MPa (1.53 kgf/cm2) [21.76 psi].
(3) Close the valve of the joint with 0.15 MPa (1.53 kgf/cm2)
[21.76 psi] pressure being applied, and hold this
condition for 1 minute. 1) 2)
(4) Make sure that the pressure is not lowered after 1 502120
minute. If the pressure drops, air leak is suspected.
1. Lubricating hole 1) Left side
2) Right side
R WARNING
Do not apply more than 0.15 MPa (1.53 kgf/cm2) [21.76 psi] pressure to the lubricating hole of the wet disc brake.
9.9 Braking Performance Test
After all of the required maintenance of the brake system is

completed, test the braking force at a speed of 10 km/h (6.2
mph). Readjust the system if necessary by referring to the
"Manual Adjustment."
9-49
9.10 Oil Pressure Measurement
(1) Block the wheels.
(2) Connect the main relief valve oil pressure gauge to the
oil pressure taps on the parking brake valve. Install the
pressure reducing valve oil pressure gauge to the
emergency relief port of parking brake. 2
501938
1. Main relief valve 2. Pressure reducing valve oil
oil pressure gauge pressure gauge
(3) For oil pressure measurement, use tools given in the

table below.
Main relief valve Rc1/8

Pressure reducing valve G1/8
(4) Measuring oil pressure

- Main relief valve
Start the engine, place all the control levers in the
neutral position, and measure the valve opening
pressure with pressure gauge.
Engine speed Low idling

Oil pressure 9.0 MPa (91.8 kgf/cm2) [1305.3 psi]
- Pressure reducing valve downstream oil pressure

Oil pressure adjustment procedure of main relief

valve
(1) Stop the engine.
(2) Remove the cap nut of the main relief valve and loosen
the lock nut.
(3) Turn the screw with a screwdriver to adjust the oil
pressure. If the oil pressure is higher than the standard
value, loosen the screw, if the pressure is lower, tighten
the screw.
(4) Start the engine again, and measure the oil pressure.
(5) If oil pressure does not meet the specification, repeat
the steps 1 to 4.
(6) When the oil pressure has reached the specification,
firmly tighten the lock nut, and install the cap nut.
Note: If the reducing valve oil pressure does not meet the
standard, disassemble the valve and replace the
spring with a new one.
9-50
9.11 Oil Pressure Measurement (Wet Disc Brakes)
(1) Block the rear wheels.

(2) Attach the oil pressure gauge to the parking brake 1
valve port.
Note: Use the emergency relief port of parking brake to
measure oil pressure.
(3) Use the oil pressure measuring tool in the table shown
below.
501939
1. Oil pressure gauge
Relief valve
G1/8
(4) Oil Pressure Measurement

Start the engine and set all the levers in the neutral
position, pull the parking brake switch, measure the
valve opening pressure using oil pressure gauge.

(5) If the oil pressure at the relief valve is different from the
standard value, stop the engine, loosen the lock nut of
the relief valve, then turn the screw with a screwdriver
to tighten the lock nut. Start the engine, and measure
oil pressure. When oil pressure reaches the standard
value, firmly tighten the lock nut.
9-51
9.12 Parking Brake Emergency Release
Release by tightening bolt

If the engine is OFF or hydraulic pressure is insufficient to disengage the parking brake, use the PKB release tool kit to
disengage the parking brake.
Note: See 6-10 "Emergency Release Method of Parking Brake" for details.
Release by external oil pressure

(1) Remove the plug (G1/8) on the emergency relief port
from the parking brake valve using a special tool.
1
501942
1. Plug for emergency relief port
Special tool
Wrench 91K67-14400
(2) Install the emergency relief connector with nut, washer,

and O-ring to the port. 1
(3) Install the emergency relief connector until it
completely comes into contact with the block seal
surface of parking brake valve, and tighten the nut to
the specified torque.
2
5 3
4 501943
1. O-ring 4. Washer
2. Emergency relief connector 5. Seal face
3. Nut
Emergency relief connector 91K67-00200

Nut 91K67-00300
Washer F2500-10000
O-ring 05500-24014
Tightening torque
19.6 N·m (2.00 kgf·m) [14.456 lbf·ft]
9-52
(4) Connect external source of oil pressure to the

emergency relief connector (G1/8), and generate
pressure to release the parking brake. 1
501944
1. External source of oil pressure
Oil pressure acceptable range

5 to 7 MPa (51 to 71 kgf/cm2) [725 to 1015 psi]
Release by external oil pressure (wet disc brakes)

(1) Remove the plug (G1/8) on the emergency relief port
from the parking brake valve.
501945
1. Plug for emergency relief port
(2) Install the emergency relief connector with nut, washer,

and O-ring to the emergency relief port.
(3) Install the emergency relief connector into the parking 1
brake valve until it completely touches to the surface of
the seal on the block of the parking brake valve, and 2
then tighten the nut to the specified torque.
5 3
4
501946
1. O-ring 4. Washer
2. Emergency relief connector 5. Seal face
3. Nut
Emergency relief connector 91K67-00200

Nut 91K67-00300
Washer F2500-10000
O-ring 05500-24014
Tightening torque
19.6 N·m (2.00 kgf·m) [14.456 lbf·ft]
9-53
(4) Connect external source of oil pressure to the

emergency relief connector (G1/8), and generate 1
pressure to release the parking brake.
501947
1. External source of oil pressure
Oil pressure acceptable range

7 to 7.6 MPa (71 to 77.5 kgf/cm2) [1015 to 1102.3 psi]
9-54
10. Troubleshooting
Item Condition Possible causes Action
Oil leaks from the wheel brake valve Replace only the piston cup if the cylinder is
Oil leaks from the wheel cylinder cup not worn.
Retighten the joint, or replace the pipe

Lack of braking force Oil leaks from oil pipe joint
and joint.
Shoe lining is worn. Replace
Shoe lining is contaminated with oil, grease, etc. Wash or replace
Less effective braking force side lining or drum is Clean with a cleaning liquid, if oil or grease
contaminated with oil or grease. on lining not removed, replace it.
Uneven braking effect Replace the drum. Readjust and retighten if

Brake drum is wobbly or loosely mounted.
loosely mounted.
Wheel tires are inflated unequally. Re-inflate the tires to the specification.
Lining is hardened by heat. Grind the surface with sandpaper.

Wheel brake
Lining is worn. Replace the shoe and lining assembly.
Brake squeaks Backing plate mounting bolts are loosened. Retighten

Wheel bearings are loosely connected. Adjust preload, and retighten.
Brake drum is contaminated. Clean with cleaning liquid.
Shoe anchor end rattles against anchor Repair or replace

Brake squeaks (clicking
Shoe ledges are excessively worn. Replace backing plate.
noise)
Piston in the wheel cylinder is excessively worn. Replace wheel cylinder.
Abnormal noise during Clearance between the lining and drum is small. Adjustment
driving Brake drum is significantly distorted. Repair or replace
Brake lining is worn out beyond service limit. Replace

Brake does not work.
Clearance between the lining and drum is large. Adjustment
Parking brake assembly is damaged. Replace
Disassemble the parking brake valve for

Brake does not work. inspection after bleeding the oil out of the
Oil line is clogged.
emergency relief port of parking brake
valve.
Parking brake Measure oil pressure of the main relief

Oil line pressure is too low. valve and reducing valve, and adjust as
required.
Brake can not be released. Solenoid valve is defective. Replace
Parking brake assembly is damaged. Replace
Electric wiring damaged Check wiring continuity.
9-55
Wet disc brakes
Item Condition Possible causes Action
Friction plate worn or facing damaged Repair leak and add brake oil.
Mating plate worn Bleeding air from brake oil line.
Brake will not work Wheel tires are inflated unequally. Replace
Friction plate worn or facing damaged Replace
Mating plate worn Replace
Wheel tires are inflated unequally. Re-inflate to specifications.

Service brake
Uneven braking effect Friction plate worn or facing damaged Replace
Mating plate worn Replace
Piston return spring deteriorated Replace

Brake return failure
Spring guide bent Replace
Inappropriate brake oil Replace with the specified brake oil.

Brake squeaks
Poor contact between friction plate and mating plate Repair
Brake spring deteriorated Replace
After draining oil from the port to forcibly

Brake will not work release the parking brake valve,
Insufficient oil line pressure
disassemble and check the parking brake
valve.
Parking brake
Measure the hydraulic pressure of the relief
Insufficient oil line pressure valve in the parking brake valve, and adjust
it.
Brake can not be released.
Parking brake valve failure Replace
Electric wiring damaged Check wiring continuity.
9-56
11. Service Data
Wheel brake
Item 4.0 to 4.5 ton classes 5.5C to 5.5 ton classes

Standard value 317.5 mm (12.500 in.) 317.5 mm (12.500 in.)
1 Inside diameter of brake drum
Limit value 318.5 mm (12.539 in.) 318.5 mm (12.539 in.)
Standard value 5.62 mm (0.2213 in.) 10.0 mm (0.394 in.)
2 Thickness of lining
Limit value 1.0 mm (0.039 in.) 1.0 mm (0.039 in.)
3 Drum-to-lining clearance (total) Standard value 0.25 to 0.40 mm( 0.0098 to 0.016 in.) 0.4 to 0.6 mm (0.016 to 0.024 in.)
Free length Standard value 120 mm (4.72 in.) 90 mm (3.54 in.)
Return 225 ± 22.6 N 294 ± 29.4 N
4 Set load Standard value
spring (22.9 ± 2.30 kgf) [50.58 ± 5.08 lbf] (30.0 ± 2.99 kgf) [66.09 ± 6.60 lbf]
Length under set load Standard value 134 mm (5.28 in.) 101.2 mm (3.984 in.)
Free length Standard value 139.3 mm (5.484 in.) 93 mm (3.66 in.)
Return 225 ± 22.6 N 245 ± 25 N
Length under set load Standard value 145.4 mm (5.724 in.) 101.2 mm (3.984 in.)
Free length Standard value 126 mm (4.96 in.) 122.5 mm (4.823 in.)
Adjusting 78.5 ± 7.8 N 78.5 ± 7.8 N
Length under set load Standard value 145.4 mm (5.724 in.) 151.8 mm (5.976 in.)
214 ± 21.4 N·m 295 ± 29.5 N·m
Backing plate mounting bolt
7 Standard value (21.8 ± 2.18 kgf·m) (30.1 ± 3.00 kgf·m)
tightening torque
[157.84 ± 15.78 lbf·ft] [217.58 ± 21.75 lbf·ft]
9-57
Item 4.0 to 4.5 ton classes 5.5C to 5.5 ton classes
1)
2
5
3 4
7
6
2)
1 2
5
4
6 7
501949
1) 4.0 to 4.5 ton classes, 2) 5.5C to 5.5 ton classes
9-58
Parking brake valve
Item All truck models

Free length Standard value 23.5 mm (0.925 in.)
1 Main relief valve spring Set load Standard value 107.7 ± 10.0 mm (4.240 ± 0.393 in.)
Length under set load Limit value 20.0 mm (0.787 in.)
2 Pressure reducing valve spring Set load Standard value 207 ± 21 mm (8.15 ± 0.82 in.)
Set length Standard value 36.6 mm (1.441 in.)
3 Solenoid valve spring Set load Standard value 10.8 ± 1.1 mm (0.425 ± 0.043 in.)
Set length Standard value 19.5 mm (0.768 in.)
39.2 ± 5.0 N·m
4 Tightening torque of main relief valve Standard value
(4.00 ± 0.50 kgf·m) [28.912 ± 3.68 lbf·ft]
Tightening torque for solenoid valve block mounting 6.0 to 8.0 N·m
5 Standard value
bolts (0.61 to 0.82 kgf·m) [4.425 to 5.901 lbf·ft]
Solenoid valve assembly mounting bolt tightening 6.0 to 8.0 N·m
6 Standard value
torque (0.61 to 0.82 kgf·m) [4.425 to 5.901 lbf·ft]
6.0 to 7.0 N·m
7 Tightening torque for plug for emergency relief port Standard value
(0.61 to 0.71 kgf·m) [4.425 to 5.163 lbf·ft]
24.5 ± 2.5 N·m
8 Tightening torque for plug nuts Standard value
(2.50 ± 0.25 kgf·m) [18.070 ± 1.84 lbf·ft]
4 1
8
8
3
6
5
501950
9-59
Wet disc brake assembly
Item All truck models

1 Thickness of mating plate Standard value 2.00 ± 0.08 mm (0.0787 ± 0.0031 in.)
Standard value 3.7 ± 0.1 mm (0.146 ± 0.003 in.)
2 Thickness of friction plate
Limit value 3.3 mm (0.130 in.)
3 Thickness of end plate Standard value 3.2 ± 0.1 mm (0.126 ± 0.003 in.)
4 Free length of return spring Standard value 24 mm (0.94 in.)
B
A
2
3 4
1
A-A
B-B 502128
9-60
9-61

Chapter 9 Brake System Overview

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Chapter 9 Brake System Overview

Uploaded by

Copyright:

Available Formats

CHAPTER 9 BRAKE SYSTEM

Chapter 9 BRAKE SYSTEM

4.0 to 4.5 ton classes

5.0C to 5.5 ton classes

Brake system (wet disk brakes)

Wet disc brakes

Wet disc brakes with option

Suggestions for disassembly

(2) Removing hold-down spring

(3) Removing shoe and lining only To remove the wheel

- Remove the adjusting lever, and fitting cable or fitting

Inspection and adjustment after disassembling

Lining thickness Standard value Service limit

- For riveted linings (5.0C to 5.5 ton classes trucks),

(3) Brake drum

Inside diameter of brake drum Standard value Service limit

(4) Adjusting screw

(5) Inspecting other parts

Suggestions for reassembly

(2) Applying grease

- Contact surface of the shoe web and the anchor pin of

(3) Installing shoe and lining assembly

(5) Installing automatic adjuster

(7) Installing brake drum

(1) Cylinder body

Item Standard value Service limit

(3) Piston cup

Item Standard value Service limit

For reassembly, follow the disassembly sequence in reverse

Inspection and adjustment after disassembling

Rer. Tightening torque

(9) Remove the mating plates, friction plates, and end

(10) Remove the brake housing.

Refer to "Inspection and Repair" of standard truck for the

Friction plate and mating plate

Item Standard value Limit value

Item Standard value

(3) Wet Disk Brake Assembly, Disassembling

- Install the brake piston and O-ring to the piston

- Insert the return spring and spring guide from the

- Install the stud bolt to the brake housing as shown.

Item Tightening torque

- Install the brake housing to the piston housing, and

Item Tightening torque

- Using a special tool, install the end plate, friction

Note: Align the recesses of splines of friction plates (5

- Install the brake cover and O-ring to the wet disc

Item Tightening torque

- Install the spacer, plug, and O-ring as shown to fix the

- Install the spacer to the gauge rod, and temporary

Item Tightening torque

Rer. Tightening torque Rer. Tightening torque

Automatic deceleration valve

Option (ProShift, Auto-Deceleration)

Rer. Tightening torque

Item Drum inside diameter Drum-to-lining clearance

(2) If the adjusting lever does not release the adjusting

(3) If the automatic adjuster does not work properly, follow

9.3 Adjustment of Brake Pedal

(2) Connect a transparent vinyl tube onto the bleeder

(8) Bleed air from left side cylinder wheel as well, by

(1) Connect a transparent vinyl tube onto the bleeder

(4) Loosen the bleeder screw and tighten the bleeder