SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1

Group 2 Operational Checks and Troubleshooting -------------------------------------------------------- 4-13
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-17
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 4-18
 SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
1) MASTER CYLINDER TYPE

1
2

B
Brake pipe C

Rear axle

Port Port name Port size

A To service brake 9/16-18UNF
B To parking brake 7/8-14UNF
C To differential lock 7/16-20UNF
Hand operated release for
D -
parking brake

Transmisson H940C4BS01

1 Brake pedal & bracket assembly 2 Reservoir tank assembly

3 Brake master cylinder

OPERATION
Compensating master cylinders overcome the problem of unequal wear between the right and left
brake. The units incorporate both master cylinder and compensating valve.
Each brake has its own master cylinder, brake pedals, servo units and associated pipework. Both
master cylinders have one common reservoir.

4-1
2) BOOSTER TYPE (OPT)

1
2

B
C

Brake pipe

D A
Rear axle
Outlet

Intlet

Port Port name Port size

A To service brake 9/16-18UNF
B To parking brake 7/8-14UNF
C To differential lock 7/16-20UNF
Hand operated release for
D -
parking brake
Transmission
H940C4BS01-1

1 Brake pedal & bracket assembly 2 Reservoir tank assembly

3 Brake valve

4-2
2. SPECIFICATION
1) SERVICE BRAKES
Item Specification
Type Oil-immersed multi-plate disc, self-adjust
Actuation Hydraulic servo assisted.
Location Inside the rear axle center casing (2 brake packs).

2) MASTER CYLINDER
Item Specification
Type Compensated master cylinder.
Number of cylinders 2
Piston diameter × stroke Ø32 × 20 mm

3) BRAKE VALVE (BOOSTER TYPE)

Item Specification
Type Boosted brake master cylinder.
Number of cylinders 2
Piston diameter × stroke Ø31.75 × 28.58 mm

4) PARKING BRAKE
Item Specification
Type Oil-immersed multi-plate disc.
Actuation Hydraulic
Location Inside the rear axle input casing.

4-3
3. MASTER CYLINDER
1) STRUCTURE

3
1
4 2

M12x1.25 R
3

4
R B
C
M8x1.25
5 M10x1.0

5
7 C
Hydraulic circuit
5

6 5

HB100BS04

1 Fork 4 Master cylinder assy 7 Hose

2 Hexagon nut 5 Cooper washer
3 Push rod 6 Screw

4-4
2) BLEEDING
(1) Low pressure bleeding
① Unscrew the bleeding valve of the brake.
② Push the brake pedal up to the stroke's
Rear axle Bleeding valve
end. (LH)
③ Screw the bleeding valve.
④ Release the brake pedal.
⑤ Wait for about 10 seconds.
⑥ Repeat point ① to ⑤ until no more air
Bleeding valve
bubbles come from the bleeding valve. (RH)

(2) High pressure bleeding HB100BS05

① Push the brake pedal.

② Unscrew the bleeding valve keeping the
pedal applied.
③ When the fluid has been flowed, screw
the bleeding valve.
④ Release the brake pedal.
⑤ Wait for about 10 seconds.
⑥ Repeat point ① to ⑤ until :
- No more air bubbles come from the
bleeding valve
- The applied pedal is not too spongy but
stiff (stroke quite short)

4-5
3) SINGLE CYLINDER OPERATION

1
2

3 4

HB100BS02

When the braking line is bleeded correctly, power cylinder is full of braking fluid.
When the cylinder is actuated, the seal (1) closes the feeding hole (2) increasing the pressure in
the braking line.
When the pre-setted pressure is achieved, the switch valve (3) closes and the line is pressurized
by the smaller bore section of the cylinder.
As the force on push rod is released, the valve (3) opens and let the brake fluid flow to the tank
through the discharge hole (4).

4-6
4) TWIN CYLINDER-COMPENSATING OPERATION

A
5

A1
5

HB100BS03

When the pedals are pushed down, the function of the power cylinders is as described in the single
cylinder operation.
If brakes require for any reason different displacements, a sort of compensation is required to avoid
different pressure in the two different lines.
Pedals operate the pistons down the bores activating the compensating valves (5).
When the valves (5) in both cylinders are activated, fluid is displaced from A to A1 via bridge pipe
M until the pressure are equalised. In this condition both compensating valves are open and both
brakes are applied evenly.

4-7
4. BRAKE VALVE (BOOSTER TYPE)
1) STRUCTURE

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22
3 23

2 24

1 26 25

H940CB4SM01

1 Push rod 10 Resevoir tank port 19 Seal

2 Check ball 11 Spring 20 Spring
3 Land 12 Brake port, LH 21 Spring
4 Inlet port 13 Spool 22 Inlet port
5 Spring 14 Brake port, RH 23 Land
6 Spring 15 Spring 24 Check ball
7 Seal 16 Resevoir tank port 25 Push rod
8 Piston 17 Valve assembly 26 Outlet port
9 Valve assembly 18 Piston

4-8
2) OPERATION
(1) Neutral position (brakes released)

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22
3 23

2 24

1 26 25

Left pedal contact Right pedal contact

Unrestricted flow
Atmospheric pressure
H940CB4SM02

Oil from the hydraulic system enters ports (4 & 22) separately. This oil flows through land areas (3
& 23), through the center of pistons (8 & 18) and on to the outlet port (26).
The two halves of the master cylinder reservoir are open to one another. Hydraulic oil enters the
master cylinder reservoir at port (10 & 16). A small flow of oil through the attached connection
keeps the master cylinder reservoir full.
In the neutral position, pistons (8 & 18) are fully retracted and valve assemblies (9 & 17) are open.
The brake system is at reservoir pressure through brake ports (12 & 14).
Pedals are held in the neutral position by springs (5 & 6) and springs (20 & 21).

4-9
(2) Both pedals applied
11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22

3 23

2 24

1 26 25

Left pedal contact Right pedal contact

Modulated pressure
Unrestricted flow
Brake system pressure
Atmospheric pressure H940CB4SM03

Oil from the hydraulic system enters ports (4 & 22) separately and drains to outlet port (26). Both
pedals are depressed forcing springs (5 & 21) to compress. Oil flowing through land areas (3 & 23)
becomes restricted. Oil flow moves to close check balls (2 & 24).
Restricted oil flow at lands (3 & 23) causes pressure to act against the large diameter of pistons (8
& 18). Pistons (8 & 18) move to compress springs (6 & 20). As more push rod displacement
occurs, valve assemblies (9 & 17) close, stopping brake system oil from moving to reservoir or
atmosphere pressure. Additional movement of the push rods and pistons (8 & 18) forces brake
system oil to the brakes causing brakes to fill through ports (12 & 14). If the brakes consume
slightly different amounts of oil, spool (13) moves against either spring (11 or 15) to satisfy the
original amount of brake oil of whichever side has the most required.
After the brakes are filled, higher brake pressure is developed by the inlet oil pressure being
modulated at lands (3 & 23), causing piston (8 & 18) to generate a higher pressure at the brake
ports. Brake pedal modulated feel is determined by the hydraulic areas of push rods (1 & 25) and
modulated pressure at lands (3 & 23).
Maximum boosted brake pressure is limited by the inlet oil pressure at ports (4 & 22).
Additional pedal effort can cause higher brake pressure and is dependent only by the amount of
pedal force applied.

4-10
(3) One pedal applied

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22

3 23

2 24

1 26 25

Right pedal contact

Left pedal contact

Modulated pressure
Unrestricted flow
Brake system pressure
Atmospheric pressure

H940CB4SM04

When only one pedal is applied, the opposite side brake remains at reservoir pressure. This
system works the same as described in page 4-10 except piston (13) moves full stroke then stops
and brake pressure is developed by the same means as described in page 4-10. The effort
required on one pedal is one half that of the effort when applying both pedals to obtain the same
brake pressure.

4-11
(4) Both pedals applied (power-off condition)

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22
3 23

2 24

1 26 25

Left pedal contact Right pedal contact

Atmospheric pressure
Brake system pressure
H940CB4SM05

When the engine in not running (power-off condition) one or both brakes can be actuated manually.
When push rods (1 & 25) are displaced by the pedals, springs (5 & 21) compress until lands (3 &
23) are mechanically closed. Additional push rod displacement forces pistons (8 & 18) to move.
Valve assemblies (9 & 17) close, stopping oil from going to the hydraulic reservoir. More push rod
travel fills the brakes and pressure is developed by providing pedal force. The amount of pressure
to the brake depends on how hard the pedals are pushed. When the pedals return to the neutral
position, valve assemblies (9 & 17) open and return brakes to reservoir pressure.

4-12